US20150192358A1 - Method and Apparatus for Cooling in Liquefaction Process - Google Patents

Method and Apparatus for Cooling in Liquefaction Process Download PDF

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US20150192358A1
US20150192358A1 US14/411,533 US201314411533A US2015192358A1 US 20150192358 A1 US20150192358 A1 US 20150192358A1 US 201314411533 A US201314411533 A US 201314411533A US 2015192358 A1 US2015192358 A1 US 2015192358A1
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stream
gas
heat exchanger
directed
expansion
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Robert Morgan
Stuart Nelmes
Nicola Castellucci
Daniel HARRIS
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Highview Enterprises Ltd
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Highview Enterprises Ltd
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Assigned to HIGHVIEW ENTERPRISES LIMITED reassignment HIGHVIEW ENTERPRISES LIMITED ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: NELMES, Stuart, MORGAN, ROBERT, CASTELLUCCI, Nicola, HARRIS, DANIEL
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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
    • F25J1/0012—Primary atmospheric gases, e.g. air
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    • 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
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    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • 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
    • F25J1/0012—Primary atmospheric gases, e.g. air
    • F25J1/0015—Nitrogen
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    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/003—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the kind of cold generation within the liquefaction unit for compensating heat leaks and liquid production
    • F25J1/0032—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the kind of cold generation within the liquefaction unit for compensating heat leaks and liquid production using the feed stream itself or separated fractions from it, i.e. "internal refrigeration"
    • F25J1/0035—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the kind of cold generation within the liquefaction unit for compensating heat leaks and liquid production using the feed stream itself or separated fractions from it, i.e. "internal refrigeration" by gas expansion with extraction of work
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    • F25J1/003—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the kind of cold generation within the liquefaction unit for compensating heat leaks and liquid production
    • F25J1/0032—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the kind of cold generation within the liquefaction unit for compensating heat leaks and liquid production using the feed stream itself or separated fractions from it, i.e. "internal refrigeration"
    • F25J1/0035—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the kind of cold generation within the liquefaction unit for compensating heat leaks and liquid production using the feed stream itself or separated fractions from it, i.e. "internal refrigeration" by gas expansion with extraction of work
    • F25J1/0037—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the kind of cold generation within the liquefaction unit for compensating heat leaks and liquid production using the feed stream itself or separated fractions from it, i.e. "internal refrigeration" by gas expansion with extraction of work of a return stream
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    • 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
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    • F25J1/004—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the kind of cold generation within the liquefaction unit for compensating heat leaks and liquid production using the feed stream itself or separated fractions from it, i.e. "internal refrigeration" by flash gas recovery
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    • 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
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    • F25J1/0201—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 only internal refrigeration means, i.e. without external refrigeration
    • F25J1/0202—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 only internal refrigeration means, i.e. without external refrigeration in a quasi-closed internal refrigeration loop
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    • F25J1/0208—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 single-component refrigerant [SCR] fluid in a closed vapor compression cycle in combination with an internal quasi-closed refrigeration loop, e.g. with deep flash recycle loop
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    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
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    • 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
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    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • 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
    • F25J1/0242—Waste heat recovery, e.g. from heat of compression
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    • F25J1/0243—Start-up or control of the process; Details of the apparatus used; Details of the refrigerant compression system used
    • F25J1/0244—Operation; Control and regulation; Instrumentation
    • F25J1/0245—Different modes, i.e. 'runs', of operation; Process control
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    • 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
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    • F25J2270/00—Refrigeration techniques used
    • F25J2270/04—Internal refrigeration with work-producing gas expansion loop
    • F25J2270/06—Internal refrigeration with work-producing gas expansion loop with multiple gas expansion loops
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/16—Mechanical energy storage, e.g. flywheels or pressurised fluids

Definitions

  • the present invention relates to cryogenic energy storage systems, and particularly to methods for the efficient balancing of the liquefaction process with the integrated use of cold recycle from an external source such as a thermal energy store.
  • Electricity transmission and distribution networks must balance the generation of electricity with the demand from consumers. This is normally achieved by modulating the generation side (supply side) by turning power stations on and off, and running some at reduced load. As most existing thermal and nuclear power stations are most efficient when run continuously at full load, there is an efficiency penalty in balancing the supply side in this way.
  • the expected introduction of significant intermittent renewable generation capacity, such as wind turbines and solar collectors, to the networks will further complicate the balancing of the grids, by creating uncertainty in the availability of parts of the generation fleet.
  • a means of storing energy during periods of low demand for later use during periods of high demand, or during low output from intermittent generators, would be of major benefit in balancing the grid and providing security of supply.
  • Power storage devices have three phases of operation: charge, store and discharge. Power storage devices generate power (discharge) on a highly intermittent basis when there is a shortage of generating capacity on the transmission and distribution network. This can be signalled to the storage device operator by a high price for electricity in the local power market or by a request from the organisation responsible for the operating of the network for additional capacity. In some countries, such as the United Kingdom, the network operator enters into contracts for the supply of back-up reserves to the network with operators of power plants with rapid start capability. Such contracts can cover months or even years, but typically the time the power provider will be operating (generating power) is very short. In addition, a storage device can provide an additional service in providing additional loads at times of oversupply of power to the grid from intermittent renewable generators.
  • Wind speeds are often high overnight when demand is low.
  • the network operator must either arrange for additional demand on the network to utilise the excess supply, through low energy price signals or specific contracts with consumers, or constrain the supply of power from other stations or the wind farms. In some cases, especially in markets where wind generators are subsidised, the network operator will have to pay the wind farm operators to ‘turn off’ the wind farm.
  • a storage device offers the network operator a useful additional load that can be used to balance the grid in times of excess supply.
  • a storage device For a storage device to be commercially viable the following factors are important: capital cost per MW (power capacity), MWh (energy capacity), round trip cycle efficiency and lifetime with respect to the number of charge and discharge cycles that can be expected from the initial investment. For widespread utility scale applications it is also important that the storage device is geographically unconstrained—it can be built anywhere, in particular next to a point of high demand or next to a source of intermittency or a bottleneck in the transmission and distribution network.
  • CES cryogenic Energy Storage
  • a CES system would, in the charge phase, utilise low cost or surplus electricity, at periods of low demand or excess supply from intermittent renewable generators, to liquefy a working fluid such as air or nitrogen. This is then stored as a cryogenic fluid in a storage tank, and subsequently released to drive a turbine, producing electricity during the discharge or power recovery phase, at periods of high demand or insufficient supply from intermittent renewable generators.
  • Cryogenic Energy Storage (CES) Systems have several advantages over other technologies in the market place, one of which is their founding on proven mature processes. Means to liquefy air, necessary in the charging phase, have existed for more than a century; early systems utilised a simple Linde cycle in which ambient air is compressed to a pressure above critical 38 bar), and progressively cooled to a low temperature before experiencing an isenthalpic expansion through an expansion device such as a Joule-Thomson valve to produce liquid. By pressurising the air above the critical threshold, the air develops unique characteristics and the potential for producing large amounts of liquid during expansion. The liquid is drained off and the remaining fraction of cold gaseous air is used to cool the incoming warm process stream. The amount of liquid produced is governed by the required amount of cold vapour and inevitably results in a low specific yield.
  • the liquefaction process within a fully integrated CES system utilises cold energy captured in the evaporation of the cryogen during the power recovery phase. This is stored by means of an integrated thermal store, such as the one detailed in GB 1115336.8, and then used during the charging phase to provide additional cooling to the main process stream in the liquefaction process.
  • the effective use of the cold recovery stream is a prerequisite to achieving an efficient cryogenic energy storage system.
  • FIG. 1 The necessary change in enthalpy that an arbitrary high pressure process stream must undergo to reach the required temperature to maximise liquid production when expanded through an expansion device such as a Joule-Thomson valve is shown in FIG. 1 .
  • a typical ideal cooling stream must similarly undergo an enthalpy change throughout the process as shown by the profile in FIG. 2 , marked ‘No Cold Recycle’.
  • the second profile in FIG. 2 demonstrates the dramatic change in required cooling (i.e. relative change of enthalpy) when large quantities of cold recycle are introduced into the system, marked ‘Cold Recycle’.
  • the present inventors have identified that there is a need for a system that can provide focused non-progressive cooling to concentrated areas of the process, in particular at the lower temperature end of the process.
  • a first aspect of the present invention addresses these needs by providing, in a first embodiment, a cryogenic liquefaction device comprising:
  • a counter-flow direction is used to mean that the second portion of the pressurised stream of gas flows through the heat exchanger in an opposite direction to the first portion of the pressurised stream of gas, for at least a part of its path through the heat exchanger.
  • the first and second portions of the pressurised stream of gas may enter the heat exchanger at opposite ends, i.e. so that the temperature difference between the entry points is maximised.
  • the first and or second portion of the pressurised stream of gas may enter the heat exchanger at a point between the ends of the heat exchanger, but flow through the heat exchanger in an opposite direction to the other of the first and second portion of the pressurised stream of gas, for at least a part of its path through the heat exchanger.
  • the cold recovery circuit comprises a thermal energy storage device, a means for circulating the heat transfer fluid (HTF), and an arrangement of conduits arranged to direct the HTF through the thermal energy storage device and into the heat exchanger.
  • HTF heat transfer fluid
  • An exemplary cold recovery circuit is described in detail in GB 1115336.8.
  • the HTF may comprise a gas or a liquid, at high or low pressure.
  • the configuration of the present invention is such that the second portion of the cooled process stream can be partially expanded through the first turbine to provide a high pressure cooling stream local to the entry point of the cold recovery stream of the cold recovery circuit. The stream can then be further expanded through the second turbine to provide significant additional cooling to the lower section of the process.
  • the present invention offers increased work output from the expansion turbines as a result of the reheating of the expanded stream, whilst also providing cooling between expansion turbines.
  • the pressurised stream of gas may consist of gaseous air.
  • the pressurised stream of gas may consist of gaseous nitrogen.
  • the pressurised stream of gas may be input into the cryogenic liquefaction device at a pressure greater than or equal to the critical pressure which, for gaseous air is 38 bar and for gaseous nitrogen is 34 bar.
  • the first portion of the pressurised stream of gas and the second portion of the pressurised stream of gas may be at the same pressure.
  • the first portion of the pressurised stream of gas and the second portion of the pressurised stream of gas may be at different pressures.
  • the first portion may be above the critical pressure, and the second portion may be below the critical pressure, or vice versa.
  • the cryogenic liquefaction device may comprise more than two expansion turbines, with turbines in both parallel and series.
  • the cryogenic liquefaction device may further comprise a third expansion turbine, wherein the operating inlet pressure of the third expansion turbine is different to at least one of the first and second expansion turbines.
  • the arrangement of conduits may be such that the third expansion turbine is in parallel with at least one of the first and second turbines such that at least a portion of the second portion of the pressurised stream of process gas is directed through the third turbine.
  • the arrangement of conduits may be such that the third expansion turbine is in series with at least one of the first and second turbines such that at least a portion of the second portion of the pressurised stream of process gas is directed through the third turbine.
  • the cryogenic liquefaction device may further comprise a refrigerant circuit which is connected to the output of the second expansion turbine via the arrangement of conduits.
  • the cryogenic liquefaction device may further comprise a second arrangement of conduits that directs a second heat transfer fluid through a closed cycle refrigeration circuit and through a localised area of the heat exchanger.
  • the second heat transfer fluid within the refrigerant circuit may comprise a gas or a liquid, at high or low pressure.
  • the cryogenic liquefaction device may further comprise a fourth expansion turbine, wherein the arrangement of conduits is arranged such that:
  • a third portion of the pressurised stream of gas is directed through the fourth expansion turbine, then through the heat exchanger in a counter-flow direction to the first portion of the pressurised stream of gas.
  • the cryogenic liquefaction device may further comprise a fifth expansion turbine, wherein the arrangement of conduits is arranged such that:
  • the third portion of the pressurised stream of gas is directed through the fifth expansion turbine after passing through the fourth expansion turbine and the heat exchanger.
  • the cryogenic liquefaction device may further comprise a second phase separator and a second expansion device, wherein the arrangement of conduits is arranged such that at least a portion of the second portion of the pressurised stream of gas is directed through the second expansion device and the second phase separator after having passed through the first expansion turbine.
  • the or each expansion device may comprise a Joule-Thomson valve, another pressure reducing valve, an expansion turbine or another work extracting device.
  • the cryogenic liquefaction device may further comprise a first compressor, wherein the arrangement of conduits is arranged such that at least a portion of the second portion of the pressurised stream of gas is directed through the first compressor before passing through the first expansion turbine.
  • the cryogenic liquefaction device may further comprise a second compressor, wherein the arrangement of conduits is arranged such that the first portion of the pressurised stream of gas is directed through the second compressor before passing through the heat exchanger.
  • the cryogenic liquefaction device may further comprise a cooler, wherein the arrangement of conduits is arranged such that the first portion of the pressurised stream of gas is directed through the cooler after passing through the second compressor and before passing through the heat exchanger.
  • the cryogenic liquefaction device may further comprise a feed stream compressor adapted to output the pressurized stream of gas, wherein the arrangement of conduits is arranged firstly such that a feed stream is directed to the input of the feed stream compressor; and secondly such that the output stream from the first phase separator joins the feed stream after passing through the heat exchanger.
  • the arrangement of conduits may be arranged such that the pressurized stream of gas output from the feed stream compressor is directed to a heat storage device before passing through the heat exchanger.
  • the arrangement of conduits may be arranged such that the pressurized stream of gas output from the heat storage device is directed to a heat rejection device before passing through the heat exchanger.
  • the first aspect of the present invention further provides a method for thermally balancing a liquefaction process with the use of cold recycle from an external thermal energy source comprising:
  • cryogenic liquefaction device Any of the optional features recited above in connection with the cryogenic liquefaction device may also be incorporated into the method of the first aspect of the present invention.
  • a second aspect of the present invention addresses these needs by providing, in a first embodiment, a cryogenic liquefaction device comprising: a heat exchanger;
  • the arrangement of conduits may be arranged such that the output stream of the first compressor joins the pressurised stream of gas.
  • the arrangement of conduits may be arranged such that the output stream of the first compressor is directed into the heat exchanger before it joins the pressurised stream of gas.
  • the arrangement of conduits may be arranged such that the output stream of the first compressor joins the pressurised stream of gas before it is directed into the heat exchanger.
  • the first compressor may be either a single stage or a multistage compressor.
  • the second aspect of the present invention further provides a method for balancing a liquefaction process with the use of cold recycle from an external thermal energy source comprising:
  • cryogenic liquefaction device Any of the optional features recited above in connection with the cryogenic liquefaction device may also be incorporated into the method of the second aspect of the present invention.
  • FIG. 1 shows a profile of the relative change in total enthalpy which a process gas undergoes during the cooling process (Relative Change of Total Enthalpy vs Cooled Stream Temperature);
  • FIG. 2 shows profiles of the relative change in total enthalpy which the cooling streams must undergo during the cooling process for systems with and without the use of large quantities of cold recycle (Relative Change of Total Enthalpy vs Cooled Stream Temperature);
  • FIG. 3 shows profiles of the relative change in total enthalpy which the cooling streams must undergo during the cooling process for ‘ideal’, ‘state of art’ and ‘present invention’ systems with the use of large quantities of cold recycle (Relative Change of Total Enthalpy vs Cooled Stream Temperature);
  • FIG. 4 shows a typical state of the art air liquefaction plant arrangement using the Claude cycle
  • FIG. 5 shows a schematic of a cryogenic energy storage system liquefaction process according to a first embodiment of the first aspect of the present invention
  • FIG. 6 shows a second embodiment of the first aspect of the present invention
  • FIG. 7 shows a third embodiment of the first aspect of the present invention.
  • FIG. 8 shows a fourth embodiment of the first aspect of the present invention.
  • FIG. 9 shows a fifth embodiment of the first aspect of the present invention.
  • FIG. 10 shows a sixth embodiment of the first aspect of the present invention.
  • FIG. 11 shows a seventh embodiment of the first aspect of the present invention.
  • FIG. 12 shows a variation of the second embodiment of the present invention
  • FIG. 13 shows a variation of the seventh embodiment of the present invention.
  • FIG. 14 shows an eighth embodiment of the present invention.
  • FIG. 15 shows a variation of the first embodiment of the present invention
  • FIG. 16 shows another variation of the first embodiment of the present invention
  • FIG. 17 shows yet another variation of the first embodiment of the present invention.
  • FIG. 18 shows a first embodiment of the second aspect of the present invention.
  • FIG. 5 The first simplified embodiment of the present invention is shown in FIG. 5 .
  • the system in FIG. 5 is similar to that of the state of the art shown in FIG. 4 in that the main process stream 31 is cooled via cold expanded air from turbines and expanded through an expansion device such as a Joule-Thomson Valve 1 to produce liquid, however the warm turbine 3 of FIG. 4 is replaced by a second cold turbine 6 aligned in series with the first cold turbine 5 .
  • the process gas in the preferred embodiment air
  • high pressure of at least the critical pressure (which for air is 38 bar, more preferably >45 bar)
  • ambient temperature ⁇ 298K
  • a cold recovery stream 30 , 50 of a cold recovery circuit of the cryogenic liquefaction device Also passing through the heat exchanger 100 is a cold recovery stream 30 , 50 of a cold recovery circuit of the cryogenic liquefaction device.
  • the cold recovery circuit comprises: a thermal energy storage device (not shown); a means for circulating a heat transfer fluid through the cold recovery circuit (not shown); and an arrangement of conduits arranged to direct the heat transfer fluid through the thermal energy storage device and the heat exchanger 100 .
  • An exemplary cold recovery circuit is described in detail in GB 1115336.8
  • This feature of the present invention provides more effective cooling than the arrangement of FIG. 4 as a result of the higher pressure cooling stream 40 , 43 around the entry point of the cold recovery stream 30 , better matching the resultant cooling demand (as shown in FIG. 3 ) than conventional layouts, where the warm turbine 3 (of FIG. 4 ) provides cooling at higher temperatures which are not required where cold recycle is available.
  • the partially expanded gas stream in passage 40 , 43 is heated to a temperature between 120-140K (in the preferred case 125K), as a result of the thermal transfer in passage 40 , 43 through heat exchanger 100 , and is further expanded through turbine 6 , to between ambient and 6 bar where it travels through passage 44 and enters the phase separator vessel 2 .
  • the gas fractions of streams 32 and 44 are combined to form output stream 34 , which travels through passage 41 , 42 through heat exchanger 100 which provides additional cooling to the high pressure process stream 35 .
  • An additional advantage of the present invention is that the typical composition of the cold process stream in stream 44 is a mixture of liquid and gaseous air.
  • the liquid fraction from the final expansion is collected within the phase separator 2 and output via passage 33 .
  • FIG. 6 A second embodiment of the current invention is shown in FIG. 6 (where like reference numerals refer to the same components as in FIG. 5 ), wherein the proportion of air separated from the main stream 31 via passage 39 is carried out later in the process and therefore at a lower temperature (between 130-170K).
  • the subsequent temperature of the cold gas after partial expansion in turbine 5 is sufficient to provide a high pressure cooling stream for the bottom end of the process stream 35 via passage 40 , 43 , after which it is expanded again through the second turbine 6 to provide additional focussed cooling in stream 34 .
  • FIG. 7 A third embodiment of the present invention is shown in FIG. 7 (where like reference numerals refer to the same components as in FIG. 5 ) wherein a third expansion turbine 7 is provided in parallel with the second turbine 6 which remains in series with turbine 5 . Similar to the second embodiment shown in FIG. 6 , a portion 39 of the cold high pressure stream 31 is partially expanded by turbine 5 to provide a high pressure cooling stream 40 at the lower end of the heat exchanger only, before it is split again into two streams 43 , 45 and expanded through the two further turbines 6 and 7 in parallel.
  • the outlet from turbine 7 is introduced typically into the phase separator 2 via passage 80 . In some embodiments where the cold recycle temperatures are low the outlet from turbine 7 may be introduced higher up the heat exchanger 100 via passage 46 .
  • FIG. 8 (where like reference numerals refer to the same components as in FIG. 7 ) details a fourth embodiment of the present invention wherein, similar to the system shown in FIG. 7 , a third expansion turbine 7 is added and placed in parallel to the second expansion turbine 6 which remains in series with the first expansion turbine 5 .
  • the expansion ratios of the second 6 and third 7 turbines are different from each other, the second expanding from around 8 bar to 4.5 bar, and the third expanding from around 8 bar to near ambient.
  • the inventors have realised that by layering multiple cooling streams in parallel as in FIG. 8 , the cooling profile demand, identified in FIG. 3 , can be more closely matched.
  • the outlet pressure of turbine 7 is substantially equal to the separator pressure 2
  • the outlet of turbine 7 is introduced to the phase separator 2 via passage 80 where liquid formed in the outlet of turbine 7 is collected.
  • FIG. 9 A further embodiment is shown in FIG. 9 (where like reference numerals refer to the same components as in FIG. 8 ).
  • This embodiment is the same as that of FIG. 8 except that the exiting gases travelling through stream 48 from the second expansion turbine 6 are removed from the process heat exchanger 100 before reaching the top.
  • the cold gases in stream 48 are further compressed, by compressor 8 , and the resultant stream 49 is cooled by a closed cycle refrigeration circuit 10 before exiting the circuit 10 as stream 51 and mixing with the high pressure process stream 31 .
  • outlet of turbine 7 may be expanded to near ambient so that this process stream can be used to drive a low pressure high grade cold store, such as that detailed in GB1115336.8.
  • FIG. 10 (where like reference numerals refer to the same components as in FIG. 5 ) is the same as that of FIG. 5 except for the addition of a closed cycle refrigeration circuit 101 to provide a local potentially high pressure cooling stream 60 to better match the cooling demand.
  • the closed cycle refrigeration circuit 101 includes compressor 102 , cooler 103 and expansion turbine 104 .
  • FIG. 11 shows a further embodiment of the present invention (where like reference numerals refer to the same components as in FIG. 5 ) wherein a warm turbine 14 and cold turbine 5 partially expand portions 60 , 39 of the cold high pressure stream 31 .
  • Streams 60 and 39 are at different temperatures and are expanded to different pressures by turbines 14 and 5 to provide streams 61 and 40 , respectively.
  • Gas in streams 61 and 40 provides focussed cooling to the high pressure stream at points 35 and 69 , before separately being expanded to between 0 and 6 bar, using further turbines 16 and 6 to provide streams 63 and 44 which are directed through heat exchanger 100 .
  • FIG. 12 A variation to the second embodiment is shown in FIG. 12 (where like reference numerals refer to the same components as in FIG. 6 ) wherein the addition of a second phase separator 18 and pressure reducing valve 19 enable the removal of additional liquid produced in stream 40 .
  • the outlet pressure of turbine 6 is equal to the separator pressure 2 and the outlet of turbine 6 is introduced to the phase separator via passage 80 where liquid formed in the outlet to turbine 7 is collected.
  • a further component which can be included in any of the previous embodiments is a closed loop refrigeration cycle (similar to cycle 101 shown in FIG. 10 ), that utilises a different working fluid to provide additional cooling at a specific section of the system where the cooling requirements are particularly high, in particular between 140 and 120K.
  • the different working fluid may comprise a refrigerant such as methane.
  • a further arrangement which can be applied to any of the previous embodiments where the high pressure stream is divided into two streams of different pressure, includes providing the first stream (that is cooled and then transferred to the expansion device) at a pressure above the critical pressure to maximise liquid production.
  • the second high pressure stream is at a different pressure (typically above the first stream pressure) and is cooled and transferred to the two or more expansion turbines to provide additional cooling to the first stream as described in the previous embodiments.
  • the second stream 58 is compressed by compressor 20 to stream 59 and is then divided into a further two or more streams 63 , 65 .
  • Stream 65 is compressed by compressor 19 and then directed, via a first stream ( 66 ), through two turbines 5 , 6 in series.
  • Stream 63 is expanded through a third turbine 21 .
  • the outlet streams 40 , 44 , 64 of the first, second and third turbines 5 , 6 , 21 provide additional cooling for the first process stream 35 prior to expansion in an expansion device such as a Joule-Thomson valve 1 .
  • the cooled gas stream 31 is fed directly from a compressor commonly referred to as a Recycle Air Compressor (RAC) and a stream 58 is split from the cooled gas stream 31 and subsequently boosted to a higher pressure by compressor 19 before being directed through expansion turbines 5 and 6 and heat exchanger 100 .
  • RAC Recycle Air Compressor
  • This additional booster component can be incorporated into any of the previous embodiments.
  • FIG. 15 shows a variation of the embodiment of FIG. 16 whereby stream 31 is fed directly from the RAC.
  • Stream 31 is split into two streams 41 and 35 ;
  • stream 41 is directed through heat exchanger 100 , where it is cooled before being directed through expansion turbines 5 and 6 and again heat exchanger 100 , while stream 35 is boosted to a higher pressure by booster 19 before being directed through heat exchanger 100 and an expansion device such as a Joule-Thomson valve 1 .
  • FIG. 16 shows a variation where stream 31 is again fed directly from the RAC and compressed to a pressure lower than the critical pressure ( ⁇ 38 bar).
  • Stream 41 splits from the main cooled stream 31 prior to the remainder of the main cooled stream 35 being boosted and subsequently cooled by boosters 19 and 20 , and coolers 10 and 22 .
  • the sub critical pressure stream 41 is cooled via heat exchanger 100 before being partially expanded, to between 5 and 20 bar, but more typically 10-14 bar, through expansion turbine 5 before passing through passage 40 , 43 , of the heat exchanger 100 , where cold thermal energy is transferred to the high pressure gas in stream in passage 73 , 38 , and being further expanded by expansion turbine 6 .
  • the additional components arranged in stream 35 can also be incorporated in any of the previous embodiments.
  • FIG. 17 shows a variation where output stream of the first phase separator 2 becomes low pressure return vapour 42 , having passed through the heat exchanger 100 , and merges with a feed stream 401 to form stream 402 .
  • the pressure of stream 402 can be between 3 barA and 15 barA, more typically 8 barA.
  • Stream 402 is directed to a single stage compressor 400 , which boosts the stream 402 to a higher pressure.
  • the output stream 403 of the single stage compressor 400 therefore has a higher pressure than stream 402 .
  • the higher pressure is at least the critical pressure (which for air is 38 bar, more preferably >45 bar).
  • the temperature of stream 403 can be between 100 deg C and 400 deg C, more typically 270 deg C.
  • Stream 403 is directed to a heat storage device 404 which removes at least some of the heat energy in the stream 403 .
  • the temperature of the output stream 405 of the heat storage device 404 can be between 20 deg C and 100 deg C, more typically 60 deg C. If the temperature of stream 405 is above ambient temperature the heat rejection device 406 may be used to cool the temperature of the stream.
  • this liquefaction cycle is used as part of a cryogenic energy storage plant it is highly preferable that the heat of compression captured by the heat storage device 404 is used in the power recovery cycle to boost the temperature of the working fluid at the inlet of the expansion turbines.
  • FIG. 18 shows an embodiment of the invention which is a further development of the air liquefaction plant arrangement of FIG. 4 .
  • the cold vapour stream 40 which is output from the expansion turbine 4 , is directed to the heat exchanger 100 rather than merging with returning stream 34 to form stream 41 as shown in FIG. 4 .
  • the cold vapour stream 40 thus gains heat as it passes through the heat exchanger 100 and exits the heat exchanger as stream 43 .
  • the temperature of stream 43 can be between 0 deg C and ⁇ 180 deg C, more typically ⁇ 117 deg C.
  • Stream 43 is directed to a compressor 300 , which boosts the stream 43 to a higher pressure.
  • the compressor 300 can be a multistage compressor or a single stage compressor.
  • the output stream 301 of the compressor 300 is directed back to heat exchanger 100 in one of two arrangements. If the temperature of stream 301 is near ambient temperature then it can be directed to merge with stream 35 outside the heat exchanger 100 . This is shown by stream 302 . Alternatively, if the temperature of stream 301 is below ambient temperature then it can be directed to merge with the stream 35 insider the heat exchanger to form stream 74 . This is shown by stream 303 .

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GB1305641.1A GB2503764B (en) 2012-07-06 2013-03-27 Method and apparatus for cooling in liquefaction process
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