US20120060553A1 - Natural gas liquefaction - Google Patents

Natural gas liquefaction Download PDF

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US20120060553A1
US20120060553A1 US13/226,633 US201113226633A US2012060553A1 US 20120060553 A1 US20120060553 A1 US 20120060553A1 US 201113226633 A US201113226633 A US 201113226633A US 2012060553 A1 US2012060553 A1 US 2012060553A1
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feed fraction
nitrogen
exchange process
heat exchanger
liquefied
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US13/226,633
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Heinz Bauer
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Linde GmbH
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Linde GmbH
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    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/0002Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the fluid to be liquefied
    • F25J1/0022Hydrocarbons, e.g. natural gas
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/003Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the kind of cold generation within the liquefaction unit for compensating heat leaks and liquid production
    • F25J1/0047Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the kind of cold generation within the liquefaction unit for compensating heat leaks and liquid production using an "external" refrigerant stream in a closed vapor compression cycle
    • F25J1/005Processes 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 expansion of a gaseous refrigerant stream with extraction of work
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/003Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the kind of cold generation within the liquefaction unit for compensating heat leaks and liquid production
    • F25J1/0047Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the kind of cold generation within the liquefaction unit for compensating heat leaks and liquid production using an "external" refrigerant stream in a closed vapor compression cycle
    • F25J1/0052Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the kind of cold generation within the liquefaction unit for compensating heat leaks and liquid production using an "external" refrigerant stream in a closed vapor compression cycle by vaporising a liquid refrigerant stream
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/006Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the refrigerant fluid used
    • F25J1/007Primary atmospheric gases, mixtures thereof
    • F25J1/0072Nitrogen
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/02Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process
    • F25J1/0203Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process using a single-component refrigerant [SCR] fluid in a closed vapor compression cycle
    • F25J1/0204Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process using a single-component refrigerant [SCR] fluid in a closed vapor compression cycle as a single flow SCR cycle
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/02Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process
    • F25J1/0221Processes 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 the cold stored in an external cryogenic component in an open refrigeration loop
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/02Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process
    • F25J1/0243Start-up or control of the process; Details of the apparatus used; Details of the refrigerant compression system used
    • F25J1/0244Operation; Control and regulation; Instrumentation
    • F25J1/0245Different modes, i.e. 'runs', of operation; Process control
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/02Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process
    • F25J1/0243Start-up or control of the process; Details of the apparatus used; Details of the refrigerant compression system used
    • F25J1/0244Operation; Control and regulation; Instrumentation
    • F25J1/0254Operation; Control and regulation; Instrumentation controlling particular process parameter, e.g. pressure, temperature
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/02Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process
    • F25J1/0243Start-up or control of the process; Details of the apparatus used; Details of the refrigerant compression system used
    • F25J1/0257Construction and layout of liquefaction equipments, e.g. valves, machines
    • F25J1/0262Details of the cold heat exchange system
    • F25J1/0264Arrangement of heat exchanger cores in parallel with different functions, e.g. different cooling streams
    • F25J1/0265Arrangement 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
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/02Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process
    • F25J1/0243Start-up or control of the process; Details of the apparatus used; Details of the refrigerant compression system used
    • F25J1/0279Compression of refrigerant or internal recycle fluid, e.g. kind of compressor, accumulator, suction drum etc.
    • F25J1/0285Combination of different types of drivers mechanically coupled to the same refrigerant compressor, possibly split on multiple compressor casings
    • F25J1/0288Combination 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
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J2210/00Processes characterised by the type or other details of the feed stream
    • F25J2210/42Nitrogen
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J2220/00Processes or apparatus involving steps for the removal of impurities
    • F25J2220/60Separating impurities from natural gas, e.g. mercury, cyclic hydrocarbons
    • F25J2220/64Separating heavy hydrocarbons, e.g. NGL, LPG, C4+ hydrocarbons or heavy condensates in general
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J2235/00Processes or apparatus involving steps for increasing the pressure or for conveying of liquid process streams
    • F25J2235/42Processes or apparatus involving steps for increasing the pressure or for conveying of liquid process streams the fluid being nitrogen
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J2245/00Processes or apparatus involving steps for recycling of process streams
    • F25J2245/90Processes or apparatus involving steps for recycling of process streams the recycled stream being boil-off gas from storage
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J2250/00Details related to the use of reboiler-condensers
    • F25J2250/02Bath type boiler-condenser using thermo-siphon effect, e.g. with natural or forced circulation or pool boiling, i.e. core-in-kettle heat exchanger
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J2270/00Refrigeration techniques used
    • F25J2270/14External refrigeration with work-producing gas expansion loop
    • F25J2270/16External refrigeration with work-producing gas expansion loop with mutliple gas expansion loops of the same refrigerant

Definitions

  • the invention relates to a method for liquefying a hydrocarbon-rich feed fraction, preferably natural gas, against a nitrogen refrigeration cycle, wherein the feed fraction is cooled against gaseous nitrogen that is to be warmed and the feed fraction is liquefied against liquid nitrogen that is to be vaporized.
  • Hydrocarbon-rich gases in particular natural gases, are liquefied commercially in a capacity range from 10 to 30,000 tons of LNG per day (tpd).
  • tpd tons of LNG per day
  • plants of medium capacity this is taken to mean liquefaction processes having a capacity between 300 and 3000 tpd of LNG—and large capacity—this is taken to mean liquefaction processes having a capacity between 3000 and 30,000 tpd of LNG—those skilled in the art attempt to optimize the operating costs by means of high efficiency.
  • this is taken to mean liquefaction processes having a capacity between 10 and 300 tpd of LNG—low capital costs are in the foreground.
  • brazed aluminum plate heat exchangers are generally used. These appliances, however, are sensitive to high thermal stresses as can arise, for example, by an oversupply of refrigerant and/or large temperature differences between warm and cold process streams. The resultant mechanical stresses can lead to damage to these appliances.
  • a method of the type in question for liquefying a hydrocarbon-rich feed fraction is known from U.S. Pat. No. 5,390,499. This method is suitable, in particular, for plants of small capacity, as explained at the outset.
  • the gas to be liquefied is cooled and liquefied against nitrogen in two separate heat exchangers. In this case the liquid low-boiling nitrogen is completely vaporized in the second heat exchanger and warmed up to a temperature at which relatively heavy crude gas components can be taken off in the liquid state by means of a separator from the gas that is to be liquefied.
  • the point at which the nitrogen vaporizes completely can vary considerably according to load. This can lead to unwanted process conditions which have the abovementioned disadvantages as a consequence.
  • the method according to the invention is suitable for use in plants of large (3000-30,000 tpd of LNG), medium (300-3,000 tpd of LNG), or small (10-300 tpd of LNG) capacities.
  • the most economical capacity range, however, is 10-300 tpd of LNG.
  • the method according to the invention is directed to liquefaction of a hydrocarbon-rich feed fraction, such as natural gas.
  • the hydrocarbon-rich feed fraction can contain 80 to 99 vol. % methane, 0.1 to 10 vol. % ethane, 0 to 5 vol. % propane, 0 to 4 vol. % C4+hydrocarbons, 0 to 10 vol. % nitrogen, 0 to 10 vol. % carbon dioxide, 0 to 1 vol. % hydrogen sulfide, up to trace amounts of other sulfur species, up to trace amounts of helium, and up to trace amounts of hydrogen.
  • FIGURE illustrates an embodiment according to the invention.
  • the hydrocarbon-rich feed fraction that is to be liquefied is fed via line 1 to a heat exchanger E 1 .
  • This is subdivided into three sections or stages a to c. The boundaries between these sections or stages are shown by the two dashed lines.
  • the hydrocarbon-rich feed fraction is cooled against superheated gaseous nitrogen, which is fed via line 9 to the heat exchanger E 1 .
  • the hydrocarbon-rich feed fraction is cooled to the extent that a separation of the heavy components from the feed fraction is possible in a separator D 2 downstream of the heat exchanger E 1 .
  • the cooled feed fraction is fed from the heat exchanger E 1 via line 1 ′ to the separator D 2 .
  • the unwanted heavy components are removed in liquid form and discharged from the process.
  • a rectification column can be used to achieve a more precise separation of relatively heavy components or higher hydrocarbons from the feed fraction.
  • the feed fraction, freed from heavy components is removed and fed to the second section b of the heat exchanger E 1 .
  • the feed fraction that is freed from heavy components is partially liquefied against gaseous nitrogen that is to be superheated 9 .
  • the feed fraction is completely liquefied against nitrogen to be partially vaporized which is fed to the heat exchanger E 1 via the line 8 .
  • the liquefied feed fraction after passage through the heat exchanger E 1 is fed to a storage vessel D 4 via line 3 , in which a control valve V 3 is arranged.
  • the liquefied product (LNG) can be discharged therefrom via line 4 .
  • the control valve V 3 serves for expanding the liquefied feed fraction to the product delivery pressure, which corresponds at least approximately to atmospheric pressure.
  • the boil-off gas formed in the storage vessel D 4 is advantageously removed via line 5 , compressed in the compressor C 3 and fed back to the feed fraction 2 which is freed from heavy components before liquefaction thereof and reliquefied in the heat exchanger E 1 .
  • This process procedure should be selected, in particular, in the case of significant temporary storage of the LNG product in an atmospheric flat-bottom tank D 4 , since the resultant boil-off gas is also processed thereby.
  • the nitrogen required for providing cold is fed to the liquefaction process via line 6 .
  • a buffer tank D 3 is provided which serves for compensating for quantitative fluctuations of the feed fraction that is to be liquefied and/or of the refrigerant nitrogen.
  • a pump P 1 liquid nitrogen is fed in the amount required to a separator D 1 via line 7 .
  • boiling nitrogen is removed and conducted via line 8 through the coldest section c of the heat exchanger E 1 .
  • the nitrogen that is partially vaporized in this case is then fed via line 8 ′ back to the separator D 1 .
  • gaseous nitrogen is taken off via line 9 and fed to the middle section b of the heat exchanger E 1 .
  • the gaseous nitrogen is conducted through the second and first sections of the heat exchanger E 1 in countercurrent flow to the feed fraction 2 that is to be cooled and partially liquefied, and is warmed and superheated in this process.
  • the superheated nitrogen is then removed from the process via the line sections 10 and 11 .
  • the boiling pressure of the gaseous nitrogen that is to be superheated 9 can be controlled.
  • this boiling pressure is adjusted to values between 5 and 30 bara, preferably between 10 and 20 bara.
  • condensation pressure of the feed fraction 2 that is freed from relatively heavy components can be controlled by means of the control valve V 2 .
  • This condensation pressure is preferably adjusted to values between 1 and 15 bara, preferably between 1 and 8 bara.
  • the temperature profile in the third section c of the heat exchanger E 1 can be controlled thereby.
  • the condensation pressure of the feed fraction is established in the section between the control valves V 2 and V 3 , and, by means of the control valve V 4 , the boiling pressure of the nitrogen in the separator D 1 and the third section c of the heat exchanger E 1 is controlled. Owing to the above-described subdivision of the heat-exchange process into a second and third section and with the phase separation in separator D 1 it can then be established exactly in what section of the heat exchanger E 1 a (partial) vaporization or superheating of the nitrogen is taking place.
  • nitrogen boiling pressure (pN 2 ) and the crude gas condensation pressure (pRG) are selected according to the inequality pRG (bara) ⁇ 0.3 pN 2 (bara) ⁇ 1, a thermal overload of the heat exchanger E 1 due to impermissibly high temperature differences can be safely avoided.
  • the associated boiling temperature is ⁇ 179° C.—it is possible to prevent reliably a temperature below the freezing temperature of methane occurring in the heat exchanger E 1 . Operating problems and possible damage due to solids formation are thereby excluded.
  • the superheated nitrogen taken off from the heat exchanger E 1 via line 10 can, alternatively to a removal via line 11 , be at least partially reliquefied.
  • the nitrogen is fed via the line sections 12 and 13 to a compression—shown in the figure by a two-stage compressor unit C 1 /C 2 , wherein a heat exchanger, E 3 or E 4 respectively, is connected downstream of each compressor unit—and then is fed via line 14 to a heat exchanger E 2 .
  • the nitrogen is reliquefied and then fed to separator D 1 via line 15 .
  • Pressure regulation of the compressor C 2 is performed by the control valve V 5 .
  • a substream of the compressed nitrogen stream is removed via line 16 , preferably expanded in a multistage manner—shown by the gas expanders X 1 and X 2 —and then conducted via line 17 through the heat exchanger E 2 in countercurrent flow to the nitrogen stream that is to be liquefied.
  • the shafts of the compressors C 1 and C 2 are preferably coupled to the shafts of the gas expanders X 2 and X 1 .
  • the liquefaction process can proceed by means of “imported” nitrogen—in this case, the superheated nitrogen is taken off from the heat exchanger E 1 via the line sections 10 and 11 —by means of reliquefied nitrogen, or by any desired combination of both modes of operation.

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Mechanical Engineering (AREA)
  • Thermal Sciences (AREA)
  • General Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Separation By Low-Temperature Treatments (AREA)

Abstract

The invention relates to a method for liquefying a hydrocarbon-rich feed fraction, preferably natural gas, against a nitrogen refrigeration cycle. A feed fraction is cooled against gaseous nitrogen that is to be warmed, and liquefied against liquid nitrogen that is to be vaporized. The feed fraction is cooled and liquefied in an at least three-stage heat-exchange process. In the first section of the heat-exchange process, the feed fraction is cooled against superheated gaseous nitrogen to the extent that an essentially complete separation of the relatively heavy components is achievable. In the second section, the feed fraction freed from relatively heavy components is partially liquefied against gaseous nitrogen that is to be superheated. In the third section, the feed fraction is liquefied against nitrogen that is to be partially vaporized.

Description

    SUMMARY OF THE INVENTION
  • The invention relates to a method for liquefying a hydrocarbon-rich feed fraction, preferably natural gas, against a nitrogen refrigeration cycle, wherein the feed fraction is cooled against gaseous nitrogen that is to be warmed and the feed fraction is liquefied against liquid nitrogen that is to be vaporized.
  • Hydrocarbon-rich gases, in particular natural gases, are liquefied commercially in a capacity range from 10 to 30,000 tons of LNG per day (tpd). In plants of medium capacity—this is taken to mean liquefaction processes having a capacity between 300 and 3000 tpd of LNG—and large capacity—this is taken to mean liquefaction processes having a capacity between 3000 and 30,000 tpd of LNG—those skilled in the art attempt to optimize the operating costs by means of high efficiency. In contrast, in the case of smaller plants—this is taken to mean liquefaction processes having a capacity between 10 and 300 tpd of LNG—low capital costs are in the foreground. In such plants, the capital cost proportion of a dedicated refrigeration plant in which the working medium used is, for example, nitrogen or a nitrogen-hydrocarbon mixture, is considerable. Therefore, generation of cold in the liquefaction plant is, if possible, dispensed with and a suitable refrigerant imported. Customarily, in this case, liquid nitrogen is used and after its use as refrigerant, is given off to the atmosphere in the gaseous state. If in nearby air separation plants unused product amounts of liquid nitrogen can be provided inexpensively, this concept for small liquefaction plants is absolutely commercially expedient.
  • For reasons of costs, in small liquid-nitrogen-cooled plants, brazed aluminum plate heat exchangers are generally used. These appliances, however, are sensitive to high thermal stresses as can arise, for example, by an oversupply of refrigerant and/or large temperature differences between warm and cold process streams. The resultant mechanical stresses can lead to damage to these appliances.
  • In addition, care must be taken to ensure that, during operation of the liquefaction process, the feed fraction does not fall below the freezing temperature. The solid point of methane at —182° C. is markedly above the atmospheric boiling temperature of nitrogen, which is −196° C. Freezing of the plant always causes an unwanted operating fault and can, in addition, have lasting damage as a consequence.
  • A method of the type in question for liquefying a hydrocarbon-rich feed fraction is known from U.S. Pat. No. 5,390,499. This method is suitable, in particular, for plants of small capacity, as explained at the outset. In the liquefaction method described in U.S. Pat. No. 5,390,499, the gas to be liquefied is cooled and liquefied against nitrogen in two separate heat exchangers. In this case the liquid low-boiling nitrogen is completely vaporized in the second heat exchanger and warmed up to a temperature at which relatively heavy crude gas components can be taken off in the liquid state by means of a separator from the gas that is to be liquefied. In a process procedure as described in U.S. Pat. No. 5,390,499, however, the point at which the nitrogen vaporizes completely can vary considerably according to load. This can lead to unwanted process conditions which have the abovementioned disadvantages as a consequence.
  • It is an object of the present invention to provide a method of the type in question for liquefying a hydrocarbon-rich feed fraction, which method avoids the abovementioned disadvantages and, in particular, to provide a method which is robust against operating faults and damage.
  • Upon further study of the specification and appended claims, other objects and advantages of the invention will become apparent.
  • For achieving these objects, a method is proposed for liquefying a hydrocarbon-rich feed fraction, which is characterized in that
      • the feed fraction is cooled and liquefied in an at least three-stage heat-exchange process,
      • wherein, in the first section of the heat-exchange process, the feed fraction is cooled against superheated gaseous nitrogen to the extent that an essentially complete separation of the relatively heavy components is achievable,
      • in the second section of the heat-exchange process, the feed fraction freed from relatively heavy components is partially liquefied against gaseous nitrogen that is to be superheated, and
      • in the third section of the heat-exchange process, the feed fraction is liquefied against nitrogen that is to be partially vaporized.
  • The method according to the invention is suitable for use in plants of large (3000-30,000 tpd of LNG), medium (300-3,000 tpd of LNG), or small (10-300 tpd of LNG) capacities. The most economical capacity range, however, is 10-300 tpd of LNG.
  • As mentioned, the method according to the invention is directed to liquefaction of a hydrocarbon-rich feed fraction, such as natural gas. For example, the hydrocarbon-rich feed fraction can contain 80 to 99 vol. % methane, 0.1 to 10 vol. % ethane, 0 to 5 vol. % propane, 0 to 4 vol. % C4+hydrocarbons, 0 to 10 vol. % nitrogen, 0 to 10 vol. % carbon dioxide, 0 to 1 vol. % hydrogen sulfide, up to trace amounts of other sulfur species, up to trace amounts of helium, and up to trace amounts of hydrogen.
  • The expression “heavy components” may be taken to mean ethane and higher molecular weight hydrocarbons.
  • Further advantageous embodiments of the method according to the invention for liquefying a hydrocarbon-rich feed fraction are characterized in that
      • the three-stage heat-exchange process is achieved in one or more heat exchangers,
      • the condensation pressure of the feed fraction freed from relatively heavy components is adjusted to values between 1 and 15 bara (absolute pressure), preferably between 1 and 8 bara, and
      • the boiling pressure of the gaseous nitrogen that is to be superheated is adjusted to values between 5 and 30 bara, preferably between 10 and 20 bara.
    BRIEF DESCRIPTION OF THE DRAWINGS
  • The invention is illustrated schematically with reference to an exemplary embodiment in the drawing and will be described extensively hereinafter with reference to the drawing. Various other features and attendant advantages of the present invention will be more fully appreciated as the same becomes better understood when considered in conjunction with the accompanying drawing wherein:
  • the FIGURE illustrates an embodiment according to the invention.
  • As shown in the FIGURE, the hydrocarbon-rich feed fraction that is to be liquefied is fed via line 1 to a heat exchanger E1. This is subdivided into three sections or stages a to c. The boundaries between these sections or stages are shown by the two dashed lines. In the warmest section a of the heat exchanger E1, the hydrocarbon-rich feed fraction is cooled against superheated gaseous nitrogen, which is fed via line 9 to the heat exchanger E1. Here, the hydrocarbon-rich feed fraction is cooled to the extent that a separation of the heavy components from the feed fraction is possible in a separator D2 downstream of the heat exchanger E1. For this purpose, the cooled feed fraction is fed from the heat exchanger E1 via line 1′ to the separator D2. From the bottom phase thereof, via line 2′, in which a valve V1 is provided, the unwanted heavy components are removed in liquid form and discharged from the process.
  • Instead of separator D2 shown in the FIGURE, a rectification column can be used to achieve a more precise separation of relatively heavy components or higher hydrocarbons from the feed fraction.
  • At the top of the separator D2, via line 2, the feed fraction, freed from heavy components, is removed and fed to the second section b of the heat exchanger E1. Therein, the feed fraction that is freed from heavy components is partially liquefied against gaseous nitrogen that is to be superheated 9. Then, in the third stage c of the heat exchanger E1, the feed fraction is completely liquefied against nitrogen to be partially vaporized which is fed to the heat exchanger E1 via the line 8.
  • The liquefied feed fraction, after passage through the heat exchanger E1 is fed to a storage vessel D4 via line 3, in which a control valve V3 is arranged. The liquefied product (LNG) can be discharged therefrom via line 4. The control valve V3 serves for expanding the liquefied feed fraction to the product delivery pressure, which corresponds at least approximately to atmospheric pressure.
  • If the nitrogen is vaporized in the third section c of the heat exchanger E1 at a pressure of greater than 15 bara, the boiling temperature thereof is no longer low enough in order to subcool the liquefied feed fraction to the extent that outgassing after expansion thereof in the control valve V3 can be prevented. In this case, the boil-off gas formed in the storage vessel D4 is advantageously removed via line 5, compressed in the compressor C3 and fed back to the feed fraction 2 which is freed from heavy components before liquefaction thereof and reliquefied in the heat exchanger E1. This process procedure should be selected, in particular, in the case of significant temporary storage of the LNG product in an atmospheric flat-bottom tank D4, since the resultant boil-off gas is also processed thereby.
  • The nitrogen required for providing cold is fed to the liquefaction process via line 6. Advantageously, a buffer tank D3 is provided which serves for compensating for quantitative fluctuations of the feed fraction that is to be liquefied and/or of the refrigerant nitrogen. By means of a pump P1, liquid nitrogen is fed in the amount required to a separator D1 via line 7. From the bottom phase of the separator D1, boiling nitrogen is removed and conducted via line 8 through the coldest section c of the heat exchanger E1. The nitrogen that is partially vaporized in this case is then fed via line 8′ back to the separator D1.
  • If the reliquefaction process that is still to be described is operated, at least temporarily the generation of cold by the reliquefaction of the nitrogen can exceed the refrigeration requirement of the natural gas liquefaction. An oversupply resulting therefrom of liquid nitrogen can be delivered into the buffer tank D3 via line 8″ and valve V6.
  • At the top of the separator D1, gaseous nitrogen is taken off via line 9 and fed to the middle section b of the heat exchanger E1. The gaseous nitrogen is conducted through the second and first sections of the heat exchanger E1 in countercurrent flow to the feed fraction 2 that is to be cooled and partially liquefied, and is warmed and superheated in this process. The superheated nitrogen is then removed from the process via the line sections 10 and 11.
  • By means of the control valve V4, the boiling pressure of the gaseous nitrogen that is to be superheated 9 can be controlled. Advantageously, this boiling pressure is adjusted to values between 5 and 30 bara, preferably between 10 and 20 bara.
  • Similarly, the condensation pressure of the feed fraction 2 that is freed from relatively heavy components can be controlled by means of the control valve V2. This condensation pressure is preferably adjusted to values between 1 and 15 bara, preferably between 1 and 8 bara.
  • By means of the control valves V2 and/or V4, the temperature profile in the third section c of the heat exchanger E1 can be controlled thereby. By means of the control valve V2, the condensation pressure of the feed fraction is established in the section between the control valves V2 and V3, and, by means of the control valve V4, the boiling pressure of the nitrogen in the separator D1 and the third section c of the heat exchanger E1 is controlled. Owing to the above-described subdivision of the heat-exchange process into a second and third section and with the phase separation in separator D1 it can then be established exactly in what section of the heat exchanger E1 a (partial) vaporization or superheating of the nitrogen is taking place.
  • By means of the subdivision of the heat-exchange process E1 into three sections a to c, it is possible to reliably prevent the phase boundary between liquid and gaseous refrigerant from migrating within the heat exchanger E1 and thereby causing unwanted thermal and mechanical stresses within the heat exchanger E1.
  • If the nitrogen boiling pressure (pN2) and the crude gas condensation pressure (pRG) are selected according to the inequality pRG (bara)≧0.3 pN2 (bara) −1, a thermal overload of the heat exchanger E1 due to impermissibly high temperature differences can be safely avoided.
  • By restricting the boiling pressure of the liquid nitrogen in the third section c of the heat exchanger E1 and of the separator D1 to at least 5 bara—the associated boiling temperature is −179° C.—it is possible to prevent reliably a temperature below the freezing temperature of methane occurring in the heat exchanger E1. Operating problems and possible damage due to solids formation are thereby excluded.
  • The superheated nitrogen taken off from the heat exchanger E1 via line 10 can, alternatively to a removal via line 11, be at least partially reliquefied. For this purpose the nitrogen is fed via the line sections 12 and 13 to a compression—shown in the figure by a two-stage compressor unit C1/C2, wherein a heat exchanger, E3 or E4 respectively, is connected downstream of each compressor unit—and then is fed via line 14 to a heat exchanger E2. Therein, the nitrogen is reliquefied and then fed to separator D1 via line 15. Pressure regulation of the compressor C2 is performed by the control valve V5. For the purpose of providing cold in the heat exchanger E2, a substream of the compressed nitrogen stream is removed via line 16, preferably expanded in a multistage manner—shown by the gas expanders X1 and X2—and then conducted via line 17 through the heat exchanger E2 in countercurrent flow to the nitrogen stream that is to be liquefied. The shafts of the compressors C1 and C2 are preferably coupled to the shafts of the gas expanders X2 and X1.
  • If the above-described reliquefaction process is operated, it is advantageous to feed to the heat exchanger E1 via line 9 only the amount of gaseous nitrogen that is required for a small positive temperature difference of approximately 3° C. between streams 1 and 10 at the warm end of the heat exchanger E1. The excess amount of cold gaseous nitrogen is used via line 9′ proportionately for reliquefaction in the heat exchanger E2.
  • In principle, the liquefaction process can proceed by means of “imported” nitrogen—in this case, the superheated nitrogen is taken off from the heat exchanger E1 via the line sections 10 and 11—by means of reliquefied nitrogen, or by any desired combination of both modes of operation.
  • The entire disclosure[s] of all applications, patents and publications, cited herein and of corresponding German Application No. DE 10 2010 044869.9, filed Sep. 9, 2010 are incorporated by reference herein.
  • The preceding examples can be repeated with similar success by substituting the generically or specifically described reactants and/or operating conditions of this invention for those used in the preceding examples.

Claims (10)

1. A method for liquefying a hydrocarbon-rich feed fraction against a nitrogen refrigeration cycle, comprising:
cooling said wherein feed fraction against gaseous nitrogen that is to be warmed, and liquefying said feed fraction against liquid nitrogen that is to be vaporized,
wherein
said feed fraction is cooled and liquefied in an at least three-stage heat-exchange process (E1 a-E1 c),
in the first section of said heat-exchange process (E1 a), said feed fraction (1) is cooled against superheated gaseous nitrogen (9) to the extent that an essentially complete separation (D2) of relatively heavy components (2′) is achievable,
in the second section of said heat-exchange process (E1 b), the feed fraction (2) freed from relatively heavy components is partially liquefied against gaseous nitrogen that is to be superheated (9), and
in the third section of said heat-exchange process (E1 c), the feed fraction (2) is liquefied against nitrogen that is to be partially vaporized (8).
2. The method according to claim 1, wherein said hydrocarbon-rich feed fraction is natural gas.
3. The method according to claim 1, wherein said three-stage heat-exchange process (E1 a-E1 c) is performed in one heat exchanger.
4. The method according to claim 2, wherein said three-stage heat-exchange process (E1 a-E1 c) is performed in one heat exchanger.
5. The method according to claim 1, wherein said three-stage heat-exchange process (E1 a-E1 c) is performed in more than one heat exchanger.
6. The method according to claim 2, wherein said three-stage heat-exchange process (E1 a-E1 c) is performed in more than one heat exchanger.
7. The method according to claim 1, wherein the condensation pressure of the feed fraction (2) freed from relatively heavy components is adjusted (V2) to a value of 1-15 bara.
8. The method according to claim 7, wherein the condensation pressure of the feed fraction (2) freed from relatively heavy components is adjusted (V2) to a value of 1-8 bara.
9. The method according to claim 1, wherein the boiling pressure of the gaseous nitrogen that is to be superheated (9) is adjusted (V4) to a value of 5-30 bara.
10. The method according to claim 9, wherein the boiling pressure of the gaseous nitrogen that is to be superheated (9) is adjusted (V4) to a value of 10-20 bara.
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US20140157824A1 (en) * 2012-12-06 2014-06-12 L'air Liquide Societe Anonyme Pour I'etude Et I'exploitation Des Procedes Georges Claude Method for improved thermal performing refrigeration cycle
FR3021091A1 (en) * 2014-05-14 2015-11-20 Ereie Energy Res Innovation Engineering METHOD AND DEVICE FOR LIQUEFACTING METHANE
EP2899116A3 (en) * 2014-01-22 2015-11-25 Meyer Werft GmbH & Co. KG Method and tank assembly for the reliquefaction and cooling of liquid natural gas in tank systems
US20180038643A1 (en) * 2016-08-05 2018-02-08 L'air Liquide, Societe Anonyme Pour L'etude Et L'exploitation Des Procedes Georges Claude Method for the integration of liquefied natural gas and syngas production
WO2018157019A1 (en) * 2017-02-24 2018-08-30 Praxair Technology, Inc. Liquid natural gas liquefier utilizing mechanical and liquid nitrogen refrigeration
WO2019101502A1 (en) * 2017-11-21 2019-05-31 L'air Liquide, Societe Anonyme Pour L'etude Et L'exploitation Des Procedes Georges Claude Bog recondenser and lng supply system provided with same
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US10634425B2 (en) * 2016-08-05 2020-04-28 L'air Liquide, Societe Anonyme Pour L'etude Et L'exploitation Des Procedes Georges Claude Integration of industrial gas site with liquid hydrogen production
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RU2775341C1 (en) * 2022-02-16 2022-06-29 Публичное акционерное общество криогенного машиностроения (ПАО "Криогенмаш") Method for liquefying natural gas (options)
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US20180038643A1 (en) * 2016-08-05 2018-02-08 L'air Liquide, Societe Anonyme Pour L'etude Et L'exploitation Des Procedes Georges Claude Method for the integration of liquefied natural gas and syngas production
US10634425B2 (en) * 2016-08-05 2020-04-28 L'air Liquide, Societe Anonyme Pour L'etude Et L'exploitation Des Procedes Georges Claude Integration of industrial gas site with liquid hydrogen production
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US20180292128A1 (en) * 2017-02-24 2018-10-11 Nick J. Degenstein Liquid natural gas liquefier utilizing mechanical and liquid nitrogen refrigeration
US11402151B2 (en) * 2017-02-24 2022-08-02 Praxair Technology, Inc. Liquid natural gas liquefier utilizing mechanical and liquid nitrogen refrigeration
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