US20130247610A1 - Method of preparing a cooled hydrocarbon stream and an apparatus therefor - Google Patents

Method of preparing a cooled hydrocarbon stream and an apparatus therefor Download PDF

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Publication number
US20130247610A1
US20130247610A1 US13/846,238 US201313846238A US2013247610A1 US 20130247610 A1 US20130247610 A1 US 20130247610A1 US 201313846238 A US201313846238 A US 201313846238A US 2013247610 A1 US2013247610 A1 US 2013247610A1
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Prior art keywords
heat exchanging
section
warm
cooling fluid
side heat
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US13/846,238
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Mohan BALASUNDAR
Adri van DRIEL
Akash GUPTA
Adriaan SPAANDER
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Shell USA Inc
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Shell Oil Co
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Assigned to SHELL OIL COMPANY reassignment SHELL OIL COMPANY ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: Van Driel, Adri, Spaander, Adriaan, Gupta, Akash, Balasundar, Mohan
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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
    • F25J1/0002—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
    • F25J1/02—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
    • F25J1/0212—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process using a multi-component refrigerant [MCR] fluid in a closed vapor compression cycle as a single flow MCR cycle
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/02—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process
    • F25J1/0211—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process using a multi-component refrigerant [MCR] fluid in a closed vapor compression cycle
    • F25J1/0214—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process using a multi-component refrigerant [MCR] fluid in a closed vapor compression cycle as a dual level refrigeration cascade with at least one MCR cycle
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/02—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process
    • F25J1/0228—Coupling of the liquefaction unit to other units or processes, so-called integrated processes
    • F25J1/0235—Heat exchange integration
    • F25J1/0237—Heat exchange integration integrating refrigeration provided for liquefaction and purification/treatment of the gas to be liquefied, e.g. heavy hydrocarbon removal from natural gas
    • F25J1/0238—Purification or treatment step is integrated within one refrigeration cycle only, i.e. the same or single refrigeration cycle provides feed gas cooling (if present) and overhead gas cooling
    • 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.
    • F25J1/029—Mechanically coupling of different refrigerant compressors in a cascade refrigeration system to a common driver
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/02—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process
    • F25J1/0243—Start-up or control of the process; Details of the apparatus used; Details of the refrigerant compression system used
    • F25J1/0279—Compression of refrigerant or internal recycle fluid, e.g. kind of compressor, accumulator, suction drum etc.
    • F25J1/0292—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
    • F25J1/02—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.
    • F25J1/0294—Multiple compressor casings/strings in parallel, e.g. split arrangement
    • 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
    • F25J5/00—Arrangements of cold exchangers or cold accumulators in separation or liquefaction plants
    • F25J5/002—Arrangements of cold exchangers or cold accumulators in separation or liquefaction plants for continuously recuperating cold, i.e. in a so-called recuperative heat exchanger
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J2220/00—Processes or apparatus involving steps for the removal of impurities
    • F25J2220/60—Separating impurities from natural gas, e.g. mercury, cyclic hydrocarbons
    • F25J2220/62—Separating low boiling components, e.g. He, H2, N2, Air
    • 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 preparing a cooled hydrocarbon stream from a hydrocarbon feed stream.
  • the cooled hydrocarbon stream may be cooled to such an extent that the hydrocarbon stream is in a fully condensed condition.
  • hydrocarbons heavier than methane are removed as far as needed to produce a liquefied hydrocarbon product stream in accordance within a desired specification.
  • Hydrocarbons heavier than butanes are removed as far as efficiently possible from the natural gas prior to any significant cooling for several reasons, such as having different freezing or liquefaction temperatures that may cause them to block parts of a methane liquefaction plant.
  • a process and apparatus for cooling a natural gas stream to a fully condensed condition is described in U.S. Pat. No. 6,370,910.
  • the natural gas stream is pre-cooled before it enters into a scrub column.
  • heavier hydrocarbons are withdrawn from the natural gas stream, to obtain a gaseous overhead stream at the top of the scrub column.
  • This gaseous overhead stream is partly condensed by indirect heat exchanging against an (auxiliary) multicomponent refrigerant evaporating at a low (auxiliary) refrigerant pressure in a(n auxiliary) heat exchanger.
  • a condensate stream is separated from the so partly condensed gaseous overhead stream, and returned to an upper part of the scrub column as reflux.
  • the pre-cooling of the natural gas stream is effected by indirect heat exchange with a bleed stream from the multicomponent refrigerant.
  • the bleed stream is passed to a pre-cooling heat exchanger via an expansion valve.
  • the multicomponent refrigerant that has evaporated in the (auxiliary) heat exchanger is removed from the heat exchanger, re-united with the bleed stream that is removed from the pre-cooling heat exchanger, and subsequently recompressed.
  • the process and apparatus described above has an inherent less than optimal efficiency, because the reflux is produced with the same refrigerant composition and pressure as are used for pre-cooling the natural gas.
  • the present invention provides a method of preparing a cooled hydrocarbon stream from a hydrocarbon feed stream, comprising:
  • the present invention provides an apparatus for preparing a cooled hydrocarbon stream from a hydrocarbon feed stream, comprising:
  • a cold side heat exchanging channel comprising a first section and a second section, wherein the first section is fluidly connected to the expander to receive the expanded cooling fluid, wherein the first section comprises a first heat exchanging fluid barrier with a first cold surface facing into the first section of the cold side heat exchanging channel and arranged to allow passage of the expanded cooling fluid in contact with the first cold surface of the first heat exchanging fluid barrier, and wherein the second section of the cold side heat exchanging channel is arranged to receive at least a residual liquid portion from the first section of the cold side heat exchanging channel, and wherein the second section comprises a second heat exchanging fluid barrier with a second cold surface facing into the second section of the cold side heat exchanging channel and arranged to allow passage of the residual liquid in contact with the second cold surface of the second heat exchanging fluid barrier,
  • a first compressor train in fluid communication with at least the second section of the cold side heat exchanging channel and comprising at least one first compressor for compressing vaporised expanded cooling fluid and vaporized residual liquid originating from the cold side heat exchanging channel to provide a compressed vapour
  • an ambient heat exchanger arranged to receive the compressed vapour and to transfer heat from the compressed vapour to ambient
  • a cooling fluid connection fluidly extending between the ambient heat exchanger and the expander by which the loop is closed
  • FIG. 1 represents a schematic process flow scheme representing a method and apparatus according to an embodiment of the invention
  • FIG. 2 schematically represents a longitudinal section of a part of a heat exchanger used in FIG. 1 ;
  • FIG. 3 represents a schematic process flow scheme representing a method and apparatus for producing a liquefied hydrocarbon stream, such as a liquefied natural gas stream, wherein the embodiment of FIG. 1 is embedded;
  • FIG. 4 schematically represents an alternative compressor train arrangement that can optionally be used in the embodiment of FIG. 3 ;
  • FIG. 5 schematically represents a schematic process flow scheme representing an alternative method and apparatus for producing a liquefied hydrocarbon stream, such as a liquefied natural gas stream, wherein the embodiment of FIG. 1 is embedded;
  • FIG. 6 schematically represents an alternative heat exchanger arrangement that can optionally be used in the embodiments of FIGS. 1 , 3 , 4 and 5 ;
  • FIG. 7 schematically represents another alternative heat exchanger arrangement that can optionally be used in the embodiments of FIGS. 1 , 3 , 4 and 5 .
  • Described below will be a method and apparatus for preparing a cooled hydrocarbon stream from a hydrocarbon feed stream.
  • the hydrocarbon feed stream is partially condensed.
  • the partially condensed hydrocarbon feed stream is then sent to a column.
  • An overhead vapour hydrocarbon stream from the column is then partially condensed by indirect heat exchanging against an expanded cooling fluid flowing through a first section of a cold side heat exchanging channel.
  • the cooling fluid consists of a mixed refrigerant composition, and liquid from the expanded cooling fluid is continuously transformed to vapour thereby forming a residual liquid portion of not evaporated expanded cooling fluid.
  • the residual liquid is used to progressively condense the hydrocarbon feed stream to produce the partially condensed hydrocarbon feed stream that is sent to the column, by allowing the hydrocarbon feed stream to lose heat to the residual liquid passing through a second section of the cold side heat exchanging channel.
  • the liquid component that is condensed out of the overhead vapour hydrocarbon stream is used as reflux for the column.
  • Relatively volatile components from the mixed refrigerant composition evaporate in the first section of the cold side heat exchanging channel using heat from the overhead vapour hydrocarbon stream from the column, leaving relatively less volatile components in the residual liquid.
  • This residual liquid is evaporated using heat from the hydrocarbon feed stream. Therefore, the reflux can be at lower temperature than the partially condensed hydrocarbon feed stream being fed to the column, while at the same time optimal use is made of the heat absorbing capacity that is available in the cooling fluid.
  • composition of the cooling fluid being evaporated in the first section is different from the residual liquid that is evaporated in the second section of the cold side heat exchanging channel, while advantageously no phase separator is necessary to achieve the different compositions.
  • the cooling fluid can be kept at essentially the same pressure in the first and second sections of the cold side heat exchanging channel, other than dynamic pressure loss inherently caused by passing through the cold side heat exchanger channel and passing from the first section to the second section of the cold side heat exchanger channel.
  • This safes equipment e.g. an expansion turbine and/or expansion valve
  • the residual liquid portion may be passed from the first section of the cold side heat exchanging channel to the second section of the cold side heat exchanging channel without changing the pressure of the residual liquid portion by more than 1 bar anywhere between these first and second sections.
  • Both the first and second sections of the cold side heat exchanging channel can be located within one single heat exchanger. Being located in a single heat exchanger may mean being located within a single shell.
  • FIG. 1 there is schematically shown an apparatus for preparing a cooled hydrocarbon stream 50 from a hydrocarbon feed stream 10 . It comprises a loop in the form of a cooling fluid loop 100 having a circulation direction 101 .
  • the cooling fluid loop 100 contains a cooling fluid consisting of a mixed refrigerant composition.
  • the present embodiment uses a so-called tube-in-shell heat exchanger 200 , which may be provided in the form of coil-wound heat exchanger.
  • the cooling fluid loop 100 comprises an expander 110 ; a cold side heat exchanging channel 120 , here as example shown as a shell side of the tube-in-shell heat exchanger 200 ; a first compressor train 130 in fluid communication with the cold side heat exchanging channel 120 ; an ambient heat exchanger 140 ; and a cooling fluid connection 150 fluidly extending between the ambient heat exchanger 140 and the expander 110 .
  • the expander 110 may be provided in any suitable form, for instance an expansion turbine, an expansion valve (such as a Joule Thomson (JT) valve) or a combination thereof.
  • JT Joule Thomson
  • the expander 110 is represented in the form of a JT valve.
  • the cold side heat exchanging channel 120 occupies the entire shell side of the tube-in-shell heat exchanger 200 .
  • a bundle break is provided in the tube-in-shell heat exchanger 200 , which separates the cold side heat exchanging channel 120 into a first section 124 and a second section 126 .
  • the location of the bundle break is schematically indicated by a dashed line 220 .
  • the first section 124 is located gravitationally higher than the second section 126 so that non-evaporated residual liquid of a cooling fluid can traverse the bundle break and flow downward from the first section 124 into the second section 126 by pull of gravity.
  • the first section 124 of the cold side heat exchanging channel 120 is on an upstream end fluidly connected to the expander 110 and on a downstream end fluidly connected to the second section 126 of the cold side heat exchanging channel 120 , via which second section 126 the first section 124 is connected to the first compressor train 130 .
  • the cooling fluid loop 100 does not comprise any phase separator between the expander 110 and the second section 126 of the cold side heat exchanging channel 120 , when the cooling fluid loop 100 is considered in the circulation direction and in a single pass of the cooling fluid through the cooling fluid loop 100 .
  • a warm side heat exchanging channel 220 is arranged in the heat exchanger, provided with a heat exchanging fluid barrier that a warm side of the heat exchanger from a cold side.
  • the warm side heat exchanging channel 220 is arranged within the shell 201 of the shell-and-tube heat exchanger 200 as a bundle of tubes traversing the shell side of the shell-and-tube heat exchanger 200 .
  • the warm side heat exchanging channel 220 comprises a first warm section 230 and a second warm section 210 .
  • FIG. 2 A specific example of a structure of the warm side heat exchanging channel within the shell is illustrated schematically in FIG. 2 , wherein a longitudinal cross section is shown though one of the tubes of the tube-in-shell heat exchanger 200 .
  • the first section 124 of the cold side heat exchanging channel 120 comprises a first heat exchanging fluid barrier 231 , with a first cold surface 232 facing into the first section 124 of the cold side heat exchanging channel 120 .
  • the second section 126 comprises a second heat exchanging fluid barrier 211 with a second cold surface 212 facing into the second section 126 of the cold side heat exchanging channel 120 .
  • the first heat exchanging fluid barrier 231 has a first warm surface 233 that faces into the first warm section 230 .
  • the first warm surface 233 faces away from the first cold surface 232 , and is in heat exchanging contact with the first cold surface 232 through the first heat exchanging fluid barrier 231 .
  • the second heat exchanging fluid barrier 211 has a second warm surface 213 that faces into the second warm section 210 of the warm side heat exchanging channel 220 .
  • the second warm surface 213 faces away from the second cold surface 212 , and is in heat exchanging contact with the second cold surface 212 through the second heat exchanging fluid barrier 211 .
  • the first and second heat exchanging fluid barriers are formed by the collective tube walls of the relevant tube bundle in the coil-wound heat exchanger. It should be noted that for reason of providing clarity within the drawing the tubes are drawn straight, while in a practical embodiment according to normal design principles known in the art the tube bundle is often arranged spiralling through the shell whereby the tubes within the bundle are spread through the majority of the available cross section within the shell, optionally intertwined with tubes belonging to other tube bundles.
  • the cooling fluid connection 150 that fluidly extends between the ambient heat exchanger 140 and the expander 110 comprises an auxiliary warm side heat exchanging channel 160 arranged in heat exchanging relationship with the cold side heat exchanging channel 120 .
  • the auxiliary warm side heat exchanging channel 160 is arranged in the heat exchanger, and it comprises a third warm section 164 arranged within the second section 126 of the cold side heat exchanging channel 120 and a fourth warm section 166 arranged with in the first section 124 of the cold side heat exchanging channel 120
  • the auxiliary warm side heat exchanging channel 160 may be provided in the form of an auxiliary tube bundle of which tubes are helically arranged within the shell preferably intertwined with the other tubes.
  • the auxiliary warm side heat exchanging channel 160 comprises a third heat exchanging fluid barrier 161 , and a fourth heat exchanging fluid barrier 166 .
  • the third heat exchanging fluid barrier 161 has a third surface 162 facing into the second section 126 of the cold side heat exchanging channel 120 , and a third warm surface 163 facing into the third warm section 164 of the auxiliary warm side heat exchanging channel 160 and facing away from the third cold surface 162 .
  • the third warm surface 163 is in heat exchanging contact with the third cold surface 162 through the third heat exchanging fluid barrier 161 .
  • the fourth heat exchanging fluid barrier 169 has a fourth warm surface 167 , which faces into the fourth warm section 166 of the auxiliary warm side heat exchanging channel 160 , and which faces away from the fourth cold surface 168 .
  • the fourth warm surface 167 is in heat exchanging contact with the fourth cold surface 168 via the fourth heat exchanging fluid barrier 166 .
  • the column 25 is fluidly connected to the source 5 of the hydrocarbon feed stream 10 via the first column inlet 21 , and via the second warm section 210 of the warm side heat exchanging channel 220 to allow passage of the hydrocarbon feed stream 10 from the source 5 to the column 25 in contact with the second warm surface 213 .
  • a reflux separator 45 is associated with the column 25 .
  • the reflux separator 45 comprises a separator inlet 41 , a liquid discharge outlet 42 and a vapour discharge outlet 43 .
  • the reflux separator 45 is in fluid communication with the column 25 via the overhead discharge outlet 26 of the column 25 , the separator inlet 41 and the first warm section 230 of the warm side heat exchanging channel 220 which is located between the overhead discharge outlet 26 of the column 25 and the separator inlet 41 .
  • the reflux separator 45 is also in fluid communication with the column 25 via a reflux conduit 47 fluidly connecting the reflux separator 45 and the column 25 via the liquid discharge outlet 42 and the second column inlet 27 .
  • a cooled hydrocarbon stream conduit 50 is fluidly connected to the vapour discharge outlet 43 of the reflux separator 45 .
  • the apparatus of FIG. 1 can be employed as follows in a method of preparing a cooled hydrocarbon stream 50 , from a hydrocarbon feed stream 10 .
  • the cooling fluid consisting of a mixed refrigerant composition
  • the cooling fluid is circulated in a cooling fluid loop 100 along the circulation direction 101 .
  • the cooling fluid passes through: the expander 110 , the cold side heat exchanging channel 120 , the compressor train 130 , the ambient heat exchanger 140 , and the cooling fluid connection 150 that fluidly extends between the ambient heat exchanger 140 and the expander 110 .
  • the passing the cooling fluid through the expander 110 provides an expanded cooling fluid.
  • the expanded cooling fluid is allowed to progressively evaporate as the expanded cooling fluid flows through the cold side heat exchanging channel 120 .
  • expanded cooling fluid is allowed to progressively evaporate by first allowing the expanded cooling fluid to flow through the first section 124 of the cold side heat exchanging channel 120 in contact with the first cold surface 232 of the first heat exchanging fluid barrier 231 , whereby liquid from the expanded cooling fluid is continuously transformed to vapour.
  • a residual liquid portion of not evaporated expanded cooling fluid is formed.
  • the residual liquid portion is allowed to continue its flow through the cold side heat exchanging channel 120 through the second section 126 thereof, and in contact with the second cold surface 212 of the second heat exchanging fluid barrier 211 whereby the residual liquid is continuously vaporized.
  • the expanded cooling fluid does not pass through any phase separator between the expander 110 and the second section 126 of the cold side heat exchanging channel 120 .
  • the vapour and the vaporized residual liquid are compressed as a combined vapour, thereby providing a compressed vapour.
  • the vapour is allowed to flow from the first section 124 to and through the second section 126 of the cold side heat exchanging channel 120 .
  • the vaporized residual liquid is mixed with the vapour from the first section 124 already in the heat exchanger.
  • the vapour could be removed from the heat exchanger separately from the vaporised residual liquid, and then combined to form a combined vapour that can be fed to the compressor train 130 as a single stream.
  • the separately removed vapour and vaporized residual liquid can be separately compressed and brought together somewhere else in the cooling fluid loop 100 .
  • heat is transferred from the compressed vapour to ambient thereby producing an ambient cooled compressed cooling fluid.
  • the heat comprises heat added during compression as well as heat gained while passing through the cold side heat exchanging channel 120 and being evaporated therein.
  • the loop is closed by again passing the cooling fluid through the expander 110 .
  • the compressed vapour flows through the optional auxiliary warm side heat exchanging channel 160 .
  • This comprises flowing through the third warm section 164 in contact with the third warm surface 162 of the third heat exchanging fluid barrier 161 and subsequently through the fourth warm section 166 in contact with the fourth warm surface 167 of the fourth heat exchanging fluid barrier 169 .
  • the cooling fluid in the cold side heat exchanging channel 120 is in contact with the respective fourth ( 168 ) and third ( 162 ) cold surfaces.
  • the compressed vapour can lose heat to the evaporating residual liquid passing through the second section 126 of the cold side heat exchanging channel 120 and subsequently to the evaporating expanded cooling fluid passing through the first section 124 of the cold side heat exchanging channel 120 .
  • the compressed vapour can condense and in so far as it has already condensed it can be subcooled prior to being expanded in the expander 110 .
  • the hydrocarbon feed stream 10 is progressively cooled as it flows through the second warm section 210 of the warm side heat exchanging channel 220 in contact with the second warm surface 213 of the second heat exchanging fluid barrier 211 .
  • a pre-cooled hydrocarbon feed stream 20 is formed, by allowing the hydrocarbon feed stream 10 to lose heat to the evaporating residual liquid passing through the second section 126 of the cold side heat exchanging channel 120 in contact with the second cold surface 212 of the second heat exchanging fluid barrier 211 .
  • the pre-cooled hydrocarbon feed stream 20 preferably consists of a mixture of vapour and liquid phases.
  • the thus pre-cooled hydrocarbon feed stream 20 is then removed from the heat exchanger and passed into the column 25 , suitably via the first column inlet 21 .
  • An overhead vapour hydrocarbon stream 30 is drawn from the column 25 and passed back to the heat exchanger.
  • the overhead vapour hydrocarbon stream 30 is progressively condensed as it flows through the first warm section 230 of the warm side heat exchanging channel 220 in contact with the first warm surface 233 of the first heat exchanging fluid barrier 231 .
  • the overhead vapour hydrocarbon stream 30 is partially condensed by allowing the overhead vapour hydrocarbon stream 30 to lose heat to the evaporating expanded cooling fluid passing through the first section 124 of the cold side heat exchanging channel 126 in contact with the first cold surface 232 of the first heat exchanging fluid barrier 231 .
  • a partially condensed hydrocarbon stream 40 is formed out of the overhead vapour hydrocarbon stream 30 .
  • the partially condensed hydrocarbon stream 40 is passed into the reflux separator 45 , suitably via the separator inlet 41 , in which reflux separator 45 the partially condensed hydrocarbon stream 40 is phase separated into a liquid component and a vaporous component.
  • the vaporous component which comprises the cooled hydrocarbon stream, is discharged via the vapour discharge outlet 43 into the cooled hydrocarbon stream conduit 50 .
  • the liquid component is discharged via the liquid discharge outlet 42 into the reflux conduit 47 and passed to and fed as reflux stream into the column 25 . This may be done for instance by force of gravity and/or with assistance of a reflux pump (not shown).
  • the temperature gradient in the column 25 is determined by the mixed refrigerant composition as the mixed refrigerant composition determines the temperature profile within the heat exchanger 200 .
  • the hydrocarbon feed stream 10 to be cooled, and ultimately preferably liquefied as will be described in embodiments below, may be derived from any suitable gas stream to be refrigerated and optionally liquefied.
  • An often used example is a natural gas stream, for instance obtained from natural gas or petroleum reservoirs, shale, or coal beds.
  • the hydrocarbon feed stream 10 may also be obtained from another source, including as an example a synthetic source such as a Fischer-Tropsch process.
  • the hydrocarbon feed stream 10 is a natural gas stream, it is usually comprised substantially of methane.
  • the hydrocarbon feed stream 10 comprises at least 50 mol % methane, more preferably at least 80 mol % methane.
  • natural gas may contain varying amounts of hydrocarbons heavier than methane such as in particular ethane, propane and the butanes (together indicated by the abbreviation C 2 -C 4 ), and possibly lesser amounts of pentanes and aromatic hydrocarbons (C 5+ hydrocarbons).
  • hydrocarbons heavier than methane such as in particular ethane, propane and the butanes (together indicated by the abbreviation C 2 -C 4 ), and possibly lesser amounts of pentanes and aromatic hydrocarbons (C 5+ hydrocarbons).
  • C 2 -C 4 ethane, propane and the butanes
  • pentanes and aromatic hydrocarbons C 5+ hydrocarbons
  • the column 25 in the present invention suitably serves to extract such C 5 + hydrocarbons so as to produce a cooled hydrocarbon stream in cooled hydrocarbon stream conduit 50 that has less than 0.1 mol. % of these C 5+ hydrocarbons.
  • natural gas liquids consisting mainly of C 2 -C 4 , hydrocarbons, particularly petroleum gas liquids in the form of C 3 -C 4 hydrocarbons (LPG) are typically recovered as well.
  • the natural gas may also contain non-hydrocarbons such as H 2 O, N 2 , CO 2 , Hg, H 2 S and other sulphur compounds, and the like.
  • the source 5 of the hydrocarbon feed stream 10 may comprise equipment to perform pre-treatment steps comprising one or more of reduction and/or removal of undesired components such as CO 2 and H 2 S or other steps such as early cooling, pre-pressurizing or the like. As these steps are well known to the person skilled in the art, their mechanisms are not further discussed here.
  • the natural gas may be dried in accordance with WO 2012/000998, which disclosure is incorporated herein by reference.
  • FIG. 3 schematically illustrates a method and apparatus for producing a liquefied hydrocarbon stream 90 , such as a liquefied natural gas stream, wherein the invention as described above is embedded.
  • the method and apparatus for producing the liquefied hydrocarbon stream 90 in accordance with FIG. 3 further comprises a main refrigeration loop 300 comprising a main cooling fluid.
  • the main cooling fluid consists of a main mixed refrigerant composition, that is different from the mixed refrigerant composition described above in that it contains relatively more volatile constituents.
  • the main refrigeration loop 300 in this embodiment is separate from the cooling fluid loop 100 in which the cooling fluid is circulated as described above. This means that under normal circulation within the respective loops, the cooling fluid and the main cooling fluid are kept separated from each other.
  • the main refrigeration loop 300 comprises one or more expanders 310 a, 310 b here as example shown in the form of expansion valves; a main cryogenic heat exchanger 400 ; a second compressor train 330 in fluid communication with the main cryogenic heat exchanger 400 ; a main ambient heat exchanger 340 ; and a main cooling fluid connection 350 fluidly extending between the main ambient heat exchanger 340 and the one or more expanders 310 a, 310 b.
  • the main cooling fluid connection 350 passes through the shell-in-tube heat exchanger 200 of the cooling fluid loop 100 via a second auxiliary warm side heat exchanging channel 360 extending through the shell side of the shell-in-tube heat exchanger 200 similar to the auxiliary warm side heat exchanging channel 160 .
  • the second auxiliary warm side heat exchanging channel 360 is connected to the main cryogenic heat exchanger 400 via a main cooling fluid separator 365 wherein the main cooling fluid can be separated in a light mixed refrigerant stream 370 a to be discharged from the top of the main cooling fluid separator 365 and a heavy mixed refrigerant stream 370 b to be discharged from the bottom of the main cooling fluid separator 365 .
  • main liquefaction processes and line ups exist which may be employed if desired.
  • the second compressor train 330 comprises at least one second compressor.
  • the at least second compressor is provided in the form of an LP compressor 331 in a first casing and an MP/HP compressor 333 combined as two successive stages in a second casing being a separate casing from the first casing.
  • the LP compressor 331 discharges into the suction inlet of the MP/HP compressor 333 via a first ambient intercooler 332 .
  • a second ambient intercooler 334 may be provided between the MP and HP stages in the MP/HP compressor 333 .
  • Alternative compressor trains can be selected instead of the specific embodiment described here.
  • the cooled hydrocarbon stream conduit 50 connects to a liquefaction passage 55 extending through the main cryogenic heat exchanger 400 .
  • the liquefaction passage 55 extends through the main cryogenic heat exchanger 400 in heat exchanging contact with the main cooling fluid that has been expanded in the one or more expanders 310 a, 310 b and fed to the main cryogenic heat exchanger 400 .
  • the cooled hydrocarbon stream is liquefied and preferably subcooled and thus converted into a raw liquefied hydrocarbon product 60 .
  • the raw liquefied hydrocarbon product 60 may be further treated by end treatment system 80 to yield for instance the liquefied hydrocarbon stream 90 and a by-product stream 70 .
  • Such by-product stream may be in vapour phase and it could be end compressed to a desired pressure in an end compressor 85 and subsequently heat exchanged against the ambient in end heat exchanger 86 .
  • the by-product stream 70 has a much lower temperature than the cooled hydrocarbon stream in cooled hydrocarbon stream conduit 50 . In such as case, preferred embodiment embodiments provide for cold recovery.
  • One suitable way is by indirectly heat exchanging the by-product stream 70 before any end compression against a slipstream of the light mixed refrigerant stream 370 a which is split off between the main cooling fluid separator 365 and the main cryogenic heat exchanger 400 and indirectly heat exchanged with the by-product stream 70 instead of in the evaporating main cooling fluid main cryogenic heat exchanger 400 .
  • Another suitable way is by indirectly heat exchanging the by-product stream 70 before any end compression against a slipstream of the cooled hydrocarbon stream which is split off from the cooled hydrocarbon stream conduit 50 between the reflux separator 45 and the liquefaction passage 55 in the main cryogenic heat exchanger 400 and is and indirectly heat exchanged with the by-product stream 70 instead of the evaporating main cooling fluid in the main cryogenic heat exchanger 400 .
  • the end treatment system 80 contains one or more expanders to depressurize the raw liquefied hydrocarbon product 60 .
  • the by-product stream 70 may suitably contain flash vapours that are generated by such depressurization.
  • the end treatment system may be selected with the aim to bring the liquefied hydrocarbon stream within a maximum specified content of light contaminants such as nitrogen and helium in the case the liquefied hydrocarbon stream consists of LNG.
  • Numerous suitable end treatment systems are known in the art and the present invention is not limited to any one specific selection of end treatment system.
  • the compressing of the vapour and the vaporized residual liquid is performed with the first compressor train 130 comprising at least the one first compressor 131
  • the circulating of the main cooling fluid comprises compressing the main cooling fluid in the second compressor train comprising the at least one second compressor ( 331 , 333 ).
  • Each of the compressors in the first compressor train 130 and of the second compressor train 330 may be provided with its own dedicated one or more compressor drivers. Suitable drivers include a steam turbine, a gas turbine (industrial frame type or, preferably, of aero derivative type), an electric motor. Sets comprising several suitable drivers in combination may be employed. Several of the compressors may be jointly driven by one or more combined drivers.
  • the LP and MP/HP compressors 331 , 333 may be jointly driven by one set of one or more drivers, whereas the at least one first compressor 131 of the first compressor train 130 may be driven by another set of one or more drivers.
  • Another option is to employ one set of drivers to drive every compressor of the first compressor train 130 and a subset of compressors of the second compressor train 330 or the other way round. This option offers advantages in terms of load balancing between the two separate cooling fluid loops.
  • FIG. 4 illustrates a special case wherein all compressors ( 131 ) of the first compressor train 130 are jointly driven together with all compressors ( 331 , 333 ) of the second compressor train 330 by one single set 335 of drivers.
  • the single set 335 of drivers may consist of a single gas turbine or a single steam turbine or a single electric motor, or any combination thereof.
  • a common drive shaft 336 mechanically drives the at least one first compressor and any other compressor in the first compressor train 130 as well as the at least one second compressor and any other compressor in the second compressor train 330 .
  • FIG. 4 shows how the invention can be embedded in a so-called double mixed refrigerant (DMR) process.
  • FIG. 5 is an example wherein the invention is embedded in a so-called single mixed refrigerant (SMR) process.
  • a combined ambient heat exchanger 540 fulfils the functions of both the ambient heat exchanger 140 and the main ambient heat exchanger 340 of FIG. 1 .
  • a cooling fluid separator 560 is provided that discharged into the main cooling fluid connection 350 and the cooling fluid connection 150 .
  • a combined SMR compressor train 530 fulfils the function of the first ( 130 ) and second ( 330 ) compressor trains described above.
  • an SMR MP/HP compressor 533 corresponds to the first compressor train 130 of FIG. 3 while an SMR LP compressor 531 together with the SMR MP/HP compressor 533 corresponds to the second compressor train 330 of FIG. 3 .
  • the SMR LP compressor 531 discharges into the suction inlet of the SMR MP/HP compressor 533 via a first SMR ambient intercooler 532 .
  • a second SMR ambient intercooler 534 may be provided between the MP and HP stages in the SMR MP/HP compressor 533 .
  • Alternative compressor train configurations can be selected instead of the specific embodiment described here.
  • the first heat exchanging fluid barrier 231 and the second heat exchanging fluid barrier 211 are both located within a single heat exchanger 200 .
  • the residual liquid portion is passed from the first section 124 of the cold side heat exchanging channel 120 to the second section 126 of the cold side heat exchanging channel 120 without changing the pressure of the residual liquid portion by more than 1 bar anywhere between these first ( 124 ) and second sections ( 126 ).
  • This is easily attainable by arranging the first ( 124 ) and second ( 126 ) sections of the cold side heat exchanging channel 120 within a single shell of a single heat exchanger.
  • An important advantage is that the compressor train 130 can be kept simple because it does not have to handle multiple input vapour streams at mutually different pressure levels.
  • the residual liquid portion is advantageously passed from the first section 124 of the cold side heat exchanging channel 120 to the second section 126 of the cold side heat exchanging channel 120 without changing the composition of the residual liquid portion anywhere between these first ( 124 ) and second sections ( 126 ).
  • This has as advantage that a minimum of equipment is needed if the composition does not need to be changed.
  • the residual liquid portion is passed from the first section 124 of the cold side heat exchanging channel 120 to the second section 126 of the cold side heat exchanging channel 120 without changing the flow rate of the residual liquid portion anywhere between these first ( 124 ) and second sections ( 126 ).
  • FIGS. 6 and 7 show alternative embodiments wherein the first warm section 230 (comprising the first heat exchanging fluid barrier) is located within a first heat exchanger 200 A and the second warm section 210 (comprising the second heat exchanging fluid barrier) is located within a second heat exchanger 200 B.
  • the first ( 200 A) and second ( 220 B) heat exchangers are interconnected to allow fluid communication between the first ( 124 ) and second ( 126 ) sections of the cold side heat exchanging channel 120 .
  • FIG. 1 shows alternative embodiments wherein the first warm section 230 (comprising the first heat exchanging fluid barrier) is located within a first heat exchanger 200 A and the second warm section 210 (comprising the second heat exchanging fluid barrier) is located within a second heat exchanger 200 B.
  • the first ( 200 A) and second ( 220 B) heat exchangers are interconnected to allow fluid communication between the first ( 124 ) and second ( 126 ) sections of the cold side heat exchanging channel 120 .
  • An advantage of the embodiment of FIGS. 6 and 7 is that it may be easier to connect the warm side heat exchanging channel 220 to the column 25 .
  • a disadvantage of the embodiment of FIG. 6 is that the interconnection that allows fluid communication between the first and second sections of the cold side heat exchanging channel may cause an additional pressure drop on the cooling fluid.
  • the cooling fluid loop 100 does not comprises any phase separator between the first section 124 and the second section 126 of the cold side heat exchanging channel 120 , when the cooling fluid loop 100 is considered in the circulation direction and in any single pass of the cooling fluid through the cooling fluid loop 100 .
  • the first and second heat exchangers are provided in the form of plate-fin type heat exchangers.
  • An advantage is that the phase separator 127 of the embodiment of FIG. 6 can suitably be avoided, as it is less challenging to convey the vapour and residual liquid portion from the first heat exchanger 200 A to the second heat exchanger 200 B as a two-phase fluid in the case of plate-fin type heat exchangers than in the case of tube-in-shell type heat exchangers.
US13/846,238 2012-03-20 2013-03-18 Method of preparing a cooled hydrocarbon stream and an apparatus therefor Abandoned US20130247610A1 (en)

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WO2021023393A1 (fr) * 2019-08-02 2021-02-11 Linde Gmbh Processus et installation de production de gaz naturel liquéfié
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AU2013201805B2 (en) 2014-09-04

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