WO2009010558A2 - Procédé et dispositif pour récupérer et fractionner un flux d'alimentation d'hydrocarbures mélangés - Google Patents

Procédé et dispositif pour récupérer et fractionner un flux d'alimentation d'hydrocarbures mélangés Download PDF

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Publication number
WO2009010558A2
WO2009010558A2 PCT/EP2008/059383 EP2008059383W WO2009010558A2 WO 2009010558 A2 WO2009010558 A2 WO 2009010558A2 EP 2008059383 W EP2008059383 W EP 2008059383W WO 2009010558 A2 WO2009010558 A2 WO 2009010558A2
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WIPO (PCT)
Prior art keywords
stream
feed stream
gas
liquid separator
initial
Prior art date
Application number
PCT/EP2008/059383
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English (en)
Other versions
WO2009010558A3 (fr
Inventor
Marco Dick Jager
Wouter Jan Meiring
Original Assignee
Shell Internationale Research Maatschappij B.V.
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Publication date
Application filed by Shell Internationale Research Maatschappij B.V. filed Critical Shell Internationale Research Maatschappij B.V.
Priority to GB0922540A priority Critical patent/GB2463202B/en
Priority to AU2008277656A priority patent/AU2008277656B2/en
Priority to EA201000224A priority patent/EA016149B1/ru
Priority to US12/669,073 priority patent/US20110036120A1/en
Publication of WO2009010558A2 publication Critical patent/WO2009010558A2/fr
Publication of WO2009010558A3 publication Critical patent/WO2009010558A3/fr

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    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C7/00—Purification; Separation; Use of additives
    • C07C7/09—Purification; Separation; Use of additives by fractional condensation
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
    • C10L3/00—Gaseous fuels; Natural gas; Synthetic natural gas obtained by processes not covered by subclass C10G, C10K; Liquefied petroleum gas
    • C10L3/06—Natural gas; Synthetic natural gas obtained by processes not covered by C10G, C10K3/02 or C10K3/04
    • C10L3/10—Working-up natural gas or synthetic 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
    • F25J1/0002—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
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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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    • F25J1/003—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the kind of cold generation within the liquefaction unit for compensating heat leaks and liquid production
    • F25J1/0047—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the kind of cold generation within the liquefaction unit for compensating heat leaks and liquid production using an "external" refrigerant stream in a closed vapor compression cycle
    • F25J1/0052—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the kind of cold generation within the liquefaction unit for compensating heat leaks and liquid production using an "external" refrigerant stream in a closed vapor compression cycle by vaporising a liquid refrigerant stream
    • F25J1/0057—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the kind of cold generation within the liquefaction unit for compensating heat leaks and liquid production using an "external" refrigerant stream in a closed vapor compression cycle by vaporising a liquid refrigerant stream after expansion of the liquid refrigerant stream with extraction of work
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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    • 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
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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    • F25J1/0214—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process using a multi-component refrigerant [MCR] fluid in a closed vapor compression cycle as a dual level refrigeration cascade with at least one MCR cycle
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/02—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process
    • F25J1/0211—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process using a multi-component refrigerant [MCR] fluid in a closed vapor compression cycle
    • F25J1/0214—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
    • F25J1/0215—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 with one SCR cycle
    • F25J1/0216—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 with one SCR cycle using a C3 pre-cooling cycle
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/02—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process
    • F25J1/0228—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
    • F25J1/0239—Purification or treatment step being integrated between two refrigeration cycles of a refrigeration cascade, i.e. first cycle providing feed gas cooling and second cycle providing overhead gas cooling
    • F25J1/0241—Purification or treatment step being integrated between two refrigeration cycles of a refrigeration cascade, i.e. first cycle providing feed gas cooling and second cycle providing overhead gas cooling wherein the overhead cooling comprises providing reflux for a fractionation step
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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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
    • F25J1/0243—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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    • 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
    • F25J3/00—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification
    • F25J3/02—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream
    • F25J3/0204—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream characterised by the feed stream
    • F25J3/0209—Natural gas or substitute 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
    • F25J3/00—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification
    • F25J3/02—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream
    • F25J3/0228—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream characterised by the separated product stream
    • F25J3/0233—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream characterised by the separated product stream separation of CnHm with 1 carbon atom or more
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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
    • F25J3/00—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification
    • F25J3/02—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream
    • F25J3/0228—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream characterised by the separated product stream
    • F25J3/0238—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream characterised by the separated product stream separation of CnHm with 2 carbon atoms or more
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    • F25J3/0242—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream characterised by the separated product stream separation of CnHm with 3 carbon atoms or more
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    • F25J2270/00—Refrigeration techniques used
    • F25J2270/02—Internal refrigeration with liquid vaporising loop
    • 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
    • F25J2270/00—Refrigeration techniques used
    • F25J2270/12—External refrigeration with liquid vaporising loop

Definitions

  • the present invention relates to a method and apparatus for recovering a mixed hydrocarbon stream from an initial feed stream, such as a natural gas stream, and fractionating the mixed hydrocarbon feed stream into one or more fractionated streams .
  • Natural gas is a useful fuel source, as well as a source of various hydrocarbon compounds. It may be produced for distribution in a pipeline grid at or near the source. Sometimes the natural gas is first liquefied in a liquefied natural gas (LNG) plant at or near the source of a natural gas stream for a number of reasons. As an example, natural gas can be stored and transported over long distances more readily as a liquid than in gaseous form because it occupies a small volume and does not need to be stored at high pressure.
  • LNG liquefied natural gas
  • natural gas comprising predominantly methane
  • the purified feed stream should be suitable for liquefaction at cryogenic temperatures.
  • the purified gas is processed through a plurality of cooling stages using heat exchangers to progressively reduce its temperature until liquefaction is achieved.
  • the liquid natural gas is then further cooled and expanded to final atmospheric pressure suitable for storage and transportation .
  • natural gas usually includes some heavier hydrocarbons and impurities, including but not limited to carbon dioxide, sulphur, hydrogen sulphide and other sulphur compounds, nitrogen, helium, water and other non-hydrocarbon acid gases, ethane, propane, butanes, C5 "1" hydrocarbons and aromatic hydrocarbons.
  • these and any other common or known heavier hydrocarbons and impurities either prevent or hinder the usual known methods of liquefying the methane, especially the most efficient methods of liquefying methane.
  • Most if not all known or proposed methods of liquefying hydrocarbons, especially liquefying natural gas are based on reducing as far as necessary the levels of at least most of the heavier hydrocarbons and impurities prior to the liquefying process.
  • Hydrocarbons heavier than methane and usually ethane are typically typically removed from the initial feed stream by partly condensing the initial feed stream thereby forming a condensed mixed hydrocarbon feed stream that is subsequently separated from the initial feed stream.
  • the condensed mixed hydrocarbon feed stream is recovered as so-called natural gas liquids (NGL) .
  • the mixed hydrocarbon feed stream containing the NGLs is often fractionated to yield valuable hydrocarbon products, either as product steams per se or for use in a process.
  • the hydrocarbon products may be used as a component of a refrigerant .
  • Fractionation typically involves separating one or more C2 "1" hydrocarbon streams from a mixed hydrocarbon stream, in particular as or as part of a multi-column natural gas liquids (NGL) recovery system and arrangement .
  • NNL multi-column natural gas liquids
  • an NGL extraction unit provides a single heavier hydrocarbon rich stream, which is subsequently used either per se, or is further divided into particular heavier hydrocarbon rich streams in a separate location or unit.
  • the fractionation of a heavier hydrocarbon rich stream can be carried out by one or more further gas/liquid separators known in the art, such as a fractionator .
  • a fractionator using one or more columns could provide individual streams of certain heavier hydrocarbons.
  • each column could be designed to provide an individual hydrocarbon stream, such as an ethane-rich stream, a propane-rich stream, a butane-rich stream, and a C5 "1" - rich stream, the latter sometimes also termed a 'light condensate stream' .
  • NTL natural gas liquids
  • an NGL extraction unit can include a fractionator, which integrally provides individual streams of certain heavier hydrocarbons such as those listed hereinbefore.
  • NGL recovery thus generally involves cooling, condensation and fractionation steps that require significant amounts of refrigeration and other power consumption. It is desirable to recover NGLs from a natural gas stream with the most efficient or minimal refrigeration power consumption.
  • US Patent 7,051,553 describes a typical gas separation process, in which a feed gas stream is cooled and liquids condensing from the cooled gas are then expanded and fractionated in a distillation column to separate residual components from desired heavier components.
  • US Pat. 7,051,553 also describes a two- column NGL recovery plant having an absorber and a distillation column, with the absorber receiving a second reflux stream comprising the cooled overhead gas of the distillation column. Cooling of the overhead gas from the distillation column is provided by a separate cooler, requiring separate power consumption.
  • US Patent 6,116,050 discloses methods for separating and recovering propane, propylene, and the C3 "1" hydrocarbons from a feed gas, to produce pipeline gas and a liquid product.
  • the methods employ sequentially configured first and second distillation columns, and a self-refrigeration system which is said to improve the separation efficiency in the first column.
  • the cooled feed gas is separated in a feed separator, and both the vapours and the liquids from the feed separator are fed into the first column. Part of the liquids conducted directly through a line into the first column, while the remaining portion is heated against a vapour overhead stream from the second column prior to introduction into the first column via the same line.
  • the present invention provides a method of recovering a mixed hydrocarbon feed stream from an initial feed stream, such as a natural gas stream, and fractionating the mixed hydrocarbon feed stream into one or more fractionated streams, the method at least comprising the step of:
  • the invention provides an apparatus for recovering a mixed hydrocarbon feed stream from an initial feed stream and fractionating the mixed hydrocarbon feed stream into one or more fractionated streams, the apparatus at least comprising: a pre-cooling heat exchanger arranged to cool the initial feed stream to provide a partly condensed initial feed stream; an initial gas/liquid separator arranged to separate the partly condensed initial feed stream into an initial gaseous overhead stream and a condensed mixed hydrocarbon stream; a stream splitter to divide the condensed mixed hydrocarbon feed stream into at least a first part-feed stream and a second part-feed stream; a first gas/liquid separator arranged to receive the first part-feed stream via a first inlet into the first gas/liquid separator, and to provide at least a first fractionated stream in the form of a first overhead gaseous stream and a first bottom liquid stream; a second gas/liquid separator arranged to receive the first bottom liquid stream, and to provide at least a second fractionated stream in the form of a second overhead gaseous stream and
  • Figure 1 is a diagrammatic scheme for a method of C2 "1" separation; and Figure 2 shows the integration of the method shown in
  • cooling of the second overhead gaseous stream from the second gas/liquid separator is provided by use of a portion of the cold energy in the condensed mixed hydrocarbon feed stream, rather than requiring any separate refrigeration or cooler involving separate power consumption, or rather than integration with a refrigeration system or circuit associated with a liquefaction process.
  • cold energy from another source such as (pre-) cooling of a hydrocarbon stream such as natural gas by a separate refrigerant, refrigeration system or circuit, need not be diverted to be involved in recovery and fractionation of the mixed hydrocarbon stream, such as in NGL recovery, thereby increasing the efficiency of other processes or sections of a liquefaction plant such as an LNG plant.
  • the cooling of the second overhead gaseous stream provides a warmer second part-feed stream, which can still be passed into the first gas/liquid separator or used otherwise.
  • the introduction of a fraction of the mixed hydrocarbon feed stream into the first gas/liquid separator at a warmer temperature reduces the energy input required from a heat source such as a reboiler to operate the first gas/liquid separator.
  • the initial feed stream is comprised substantially of methane.
  • the feed stream comprises at least 60 mol% methane, more preferably at least 80 mol% methane.
  • mixed hydrocarbon feed stream relates to a feed stream comprising methane and one or more hydrocarbons selected from the group comprising: ethane, propane, butanes, pentanes, and Cg + hydrocarbons .
  • the mixed hydrocarbon feed stream may be provided from any suitable source.
  • the mixed hydrocarbon feed stream is provided from an initial feed stream.
  • the initial feed stream may be any suitable hydrocarbon stream such as, but not limited to, a hydrocarbon-containing gas stream to be cooled.
  • a natural gas stream obtained from a natural gas or petroleum reservoir.
  • the initial feed stream may also be obtained from another source, such as a refinery and/or including a synthetic source such as a Fischer-Tropsch process.
  • C2 "1" " as used herein relates to one or more components selected from the group comprising: ethane, propane, butanes, pentanes, and Cg + hydrocarbons.
  • C3 "1” as used herein relates to one or more components selected from the group comprising: propane, butanes, pentanes, and C6+ hydrocarbons .
  • C4 "1” ", etc. are similarly defined starting with “butanes”, etc.
  • Each gas/liquid separator of the present invention may involve one or more columns, and one or each of such columns could provide individual liquid streams of certain heavier hydrocarbons such as ethane, propane, etc ..
  • C4 "1" , etc. may still comprise a minor ( ⁇ 10 mol%) amount of methane; each such stream is preferably >80 mol%, more preferably >95 mol%, of its one or more components as defined above.
  • the division of a stream such as a feed stream into two or more part streams may be carried out using any suitable stream splitter or divider, which may be a distinct unit, or a simpler division of a line such as a T-Piece .
  • the method according to the present invention is applicable to various initial hydrocarbon- containing feed streams, it is particularly suitable for natural gas streams to be liquefied. As the person skilled readily understands how to liquefy a hydrocarbon stream, this will herein only be discussed at a basic level of detail.
  • Figure 1 shows a simplified and general scheme 1 of a method for separating one or more C2 "1" hydrocarbon streams from a mixed hydrocarbon feed stream recovered from an initial feed stream, such as natural gas.
  • the scheme of Figure 1 can be part of a liquefied natural gas plant 2 shown in Figure 2.
  • Figure 1 illustrates a method and apparatus for separating one or more C2 "1" hydrocarbon streams from an initial feed stream such as natural gas .
  • the apparatus comprises : means to separate a mixed hydrocarbon feed stream 10 from the initial feed stream 8; a stream splitter 36 to divide the mixed hydrocarbon feed stream 10 into at least a first part-feed stream 20 and a second part-feed stream 30; a first gas/liquid separator 14 to receive the first part-feed stream 20, and to provide at least a first overhead gaseous stream 40 and a first bottom liquid stream 50; a second gas/liquid separator 22 to receive the first bottom liquid stream 50, and to provide at least a second overhead gaseous stream 70 and a second bottom liquid stream 80; and a heat exchanger 26 to receive the second part-feed stream 30 and the second overhead gaseous stream 70, and to provide a cooled second overhead gaseous stream 70a and a warmer second part-feed stream 30b.
  • the method as illustrated in Figure 1 at least comprises the steps of: providing a mixed hydrocarbon feed stream 10 from an initial feed stream 8; dividing the mixed hydrocarbon feed stream 10 into at least a first part-feed stream 20 and a second part-feed stream 30; passing the first part-feed stream into a first gas/liquid separator 14 to provide at least a first gaseous overhead stream 40 and a first bottom liquid stream 50; passing the first bottom liquid stream 50 into a second gas/liquid separator 22 to provide at least a second gaseous overhead stream 70 and a second bottom liquid stream 80; and cooling the second overhead gaseous stream 70 by heat exchange against the second part-feed stream 30.
  • the first and second gas/liquid separators may be any form of separator such as a distillation column adapted to provide at least one gaseous stream, usually being enriched in one or more lighter hydrocarbons, and at least one liquid stream, usually being enriched in one or more heavier hydrocarbons .
  • An example of such a separator is a "de-methanizer” designed to provide a methane-enriched overhead stream, and one or more C2 "1" enriched liquid steams at or near the bottom.
  • de-ethanizers and “de-propanizers”, etc., known in the art .
  • the first bottom liquid stream will be a C2 "1" hydrocarbon stream.
  • the second bottom liquid stream will be a C3 "1" hydrocarbon stream, and the second overhead gaseous stream is preferably >60 mol% ethane, more preferably >85 and even more preferably >90 mol% ethane .
  • Figure 1 shows an initial feed stream 8 containing natural gas, which is cooled by a pre- cooling heat exchanger 32 to provide a cooled and partly condensed initial stream 8a.
  • the pre-cooling heat exchanger 32 may comprise one or more heat exchangers either in parallel, series or both, in a manner known in the art. Cooling is provided by a first refrigerant stream 100, which is warmed in the pre-cooling heat exchanger 32 to create a warmed refrigerant stream 100a.
  • This cooling of the initial feed stream 8 may be part of a liquefaction process, such as a pre-cooling stage involving a propane refrigerant circuit as described hereinafter in relation to Figure 2, or a separate process .
  • Cooling of the initial feed stream 8 may involve reducing the temperature of the initial feed stream 8 to below -0 0 C, for example, in the range -10 0 C to -40 0 C.
  • the cooled initial stream 8a is passed into an initial gas/liquid separator such as a scrub column 34, operating at an above ambient pressure in the manner known in the art.
  • the scrub column 34 provides a condensed mixed hydrocarbon feed stream 10, and an initial gaseous overhead steam 110.
  • the initial gaseous overhead stream 110 usually comprises greater than 80 mol% methane. It is typically a methane-enriched stream compared to the cooled initial stream 8a.
  • the mixed hydrocarbon feed stream 10 comprises methane and one or more C2 "1" hydrocarbons.
  • the proportion of methane in the mixed hydrocarbon feed stream is 30-50 mol%, with a significant fraction of ethane and propane, such as 5-10 mol% each.
  • the mixed hydrocarbon feed stream 10 is divided by a steam splitter 36 into a first part-feed stream 20 and a second part-feed stream 30.
  • the division of the mixed hydrocarbon feed stream 10 could be based on any ratio of mass and/or volume and/or flow rate. The ratio may be based on the size or capacity of the subsequent parts, systems or units, or the size, capacity or cold energy for the second part-feed stream 30 and duty of the heat exchanger 26 (discussed hereinafter) .
  • the first part-feed stream 20 will be between 20 to 70 mass%, preferably 30 to 50 mass% and more preferably 40 vol%, of the mixed hydrocarbon feed stream 10.
  • the first part-feed stream 20 passes through a valve 12 to provide a reduced pressure first part-feed stream 20a, which then enters a first gas/liquid separator such as a first distillation column 14 through a first inlet at or near the top of the first distillation column 14.
  • the reduced pressure first part-feed stream 20a is typically a mixed phase stream, and the first distillation column 14 is adapted to separate the gaseous and vapour phases, so as to provide a first overhead gaseous stream 40 and a first bottom liquid stream 50.
  • first distillation column 14 The nature of the streams provided by the first distillation column 14 can be varied according to the size and type of distillation column, and its operating conditions and parameters, in a manner known in the art.
  • first overhead gaseous stream 40 it is desired for the first overhead gaseous stream 40 to be methane- enriched, preferably to be >90 mol% methane.
  • This methane-enriched stream 40 could be added into other parts of a liquefaction plant to provide for example further LNG, or it could be used as fuel.
  • the first distillation column 14 also includes a first reboiler 17 and a bottom return stream 60, typically in the form of a reboiler vapour return stream, in a manner known in the art .
  • the first bottom liquid stream 50 will predominantly be C2 + hydrocarbons, such as >90 or >95 mol% of ethane and heavier hydrocarbons.
  • the first bottom liquid stream 50 is cooled by one or more ambient coolers, such as a water and/or air cooler 16, followed by a passage through a valve 18 to provide a reduced pressure first bottom stream 50a, which enters through inlet 42 into a second gas/liquid separator such as a second distillation column 22.
  • a second gas/liquid separator such as a second distillation column 22.
  • the second distillation column 22 provides a second overhead gaseous stream 70 being predominantly ethane, preferably >85 or >90 mol% ethane, and a second bottom liquid stream 80, generally being >98% propane and heavier hydrocarbons.
  • the second distillation column 22 also includes a reboiler 27 and a reboiler vapour return stream 90.
  • the cooling of the second overhead gaseous stream 70 preferably results in condensation of at least part, preferably all, of the second overhead gaseous stream.
  • a condensed fraction may be used as a reflux stream 70b for the second gas/liquid separator 22.
  • the method thus further provides the steps of: (i) dividing a cooled second gaseous overhead stream 70a provided by step (g) into two or more fractions (70b, 70c) ; and
  • the fraction of the second overhead gaseous stream in step (i) can be used to provide reflux to the distillation column .
  • the second overhead gaseous stream 70 is cooled by a separate or external cooler as shown in US 7,051,553 B2, or by the pre-cooling heat exchanger 32.
  • a separate or external cooler as shown in US 7,051,553 B2
  • the pre-cooling heat exchanger 32 takes away some of the cooling power of the pre-cooling heat exchanger 32 from cooling of the initial feed stream 8. Both of these situations reduce the efficiency of an LNG plant. Both also create complicated integration between the fractionation arrangement and the remainder of a liquefaction plant .
  • the second part-feed stream 30 (from the mixed hydrocarbon feed stream 10), after passing through a valve 24 to provide a reduced pressure second part stream 30a, preferably has a temperature that is low enough, such as between 0 0 C and -50 0 C, to provide cooling in a heat exchanger 26 to the second overhead gaseous stream 70.
  • the heat exchanger 26 may be one or more heat exchangers in parallel, series or both. In embodiments, heat exchanger 26 may be referred to as a reflux heat exchanger .
  • the cold energy of the reduced pressure second part- feed stream 30a withdraws warmth from the second overhead gaseous stream 70 to at least partially condense, preferably fully condense, the second overhead gaseous stream 70 in the heat exchanger 26, and provide an at least partly condensed second stream 70a.
  • cooling of the second overhead gas stream 70 is achieved without the need for a separate source of cooling, making the arrangement for NGL recovery shown in Figure 1 independent of any refrigeration system.
  • the at least partly condensed second stream 70a can be divided by a stream splitter 44 into a reflux stream 70b, and a product stream 70c.
  • the product stream 70c could be provided as a separate product stream for use outside a liquefaction plant, or as a refrigerant or as a component of a refrigerant in a liquefaction plant, such as in a mixed refrigerant known in the art.
  • the heat exchange of the second overhead gaseous stream 70 and the second part-feed stream 30a also provides a warmer second part-feed stream 30b, which can be passed into the first distillation column 14, preferably between the inlet 38 for the first part-feed stream 20a and the bottom return stream 60, e.g. via an inlet 39 into the first distillation column 14, located gravitationally lower than inlet 38.
  • the bottom return stream 60 may be fed back into the first distillation column 14 via return stream inlet 41.
  • the arrangement shown in Figure 1 is for the separation of C]_ and C2 streams 40, 70 from a mixed hydrocarbon feed stream 10, resulting in a remaining C3 "1" stream 80.
  • this arrangement is equally applicable to provide, for example, a C]_ stream and a mixed C2/3 stream, with the remainder being a C4 "1" stream, or to provide separate C]_, C2 and C3 streams, with a remaining C4 "1" stream. All such configurations and arrangements are known to the person skilled in the art in relation to NGL recovery.
  • the method of the present invention is equally applicable to use with two other gas/liquid separators using a mixed hydrocarbon feed stream and adapted to provide different product streams .
  • the method of the present invention is applicable to an arrangement involving more than two gas/liquid separators, where more than three product streams such as separate C3, C4 and
  • the second part-feed stream 30 could be divided into two or more fractions for cooling other overhead gaseous streams (such as from a de-propanizer, etc.), thus further reducing or eliminating the requirement for separate coolers or heat exchangers for each overhead stream.
  • the mixed hydrocarbon feed stream 10 is provided from the initial feed stream 8 by separating the initial feed stream 8 into the mixed hydrocarbon feed stream 10 and the initial gaseous overhead stream 110.
  • the latter may in practical situations often be a methane-enriched stream.
  • the initial gaseous overhead stream 110 may be fed into a gas grid to distribute the methane-enriched stream as gas to market. Before feeding into a grid, the initial gaseous overhead stream 110 may, however, be subjected to other processing steps such as further treating to change the composition and/or cooling, preferably liquefying, to provide a cooled hydrocarbon stream, preferably LNG.
  • the present invention further provides a method of cooling an initial feed stream such as a hydrocarbon stream such as natural gas comprising at least the steps of:
  • the initial gaseous overhead stream is preferably cooled without passing it through the first gas/liquid separator. It may be cooled by passing the initial gaseous overhead stream to one or more heat exchangers where it is allowed to exchange heat against one or more refrigerants being cycled in one or more refrigerant cycles .
  • Figure 2 shows a LNG plant 2 incorporating the C2 "1" separation arrangement 1 shown in Figure 1.
  • FIG. 2 shows an initial feed stream 8 being cooled by three pre-cooling heat exchangers 46 (similar or equivalent to the pre-cooling heat exchanger 32 in Figure 1) to provide a cooled initial stream 8a, which is divided by a divider 29 into a first stream 9 which passes directly into a scrub column 34, and a second stream 9a which passes into a main cryogenic heat exchanger 23 to provide a cooler initial feed stream 9b, which also passes into the scrub column 34 at a higher level than the first stream 9.
  • pre-cooling heat exchangers 46 similar or equivalent to the pre-cooling heat exchanger 32 in Figure 1
  • the scrub column 34 provides a condensed mixed hydrocarbon feed stream 10.
  • This mixed stream 10 is divided by a stream splitter 36 into a first part-feed stream 20 and second part-feed stream 30, whose passage is as hereinbefore described with relation to Figure 1.
  • first part-feed stream 20 passes through a valve to provide a reduced pressure first part- feed stream 20a, which then enters a first distillation column 14.
  • the distillation column 14 provides a first overhead gaseous stream 40 generally being methane and labelled "Cl" in Figure 2, and a first bottom liquid stream 50 which passes after cooling and expansion into a second distillation column 22.
  • the second distillation column 22 provides a second overhead gaseous stream 70 which is cooled in the heat exchanger 26 against the reduced pressure second part stream 30a to provide a cooled second overhead stream in the form of an at least partly, preferably fully, condensed second stream 70a, which is divided into a reflux stream 70b and a product stream 70c, which is predominantly ethane and labelled "C2" in Figure 2.
  • the second distillation column 22 also provides a second bottom liquid stream 80 being a C3 "1" stream, which, after expansion, can be passed into a further gas/liquid separator such as a third distillation column 52, optionally also being a de-propanizer .
  • the third distillation column 52 can provide a third overhead stream 140 (which after cooling can provide a "C3" product stream comprising for example >95 mol%, preferably 99 mol%, propane), and a third bottom liquid stream 130 being a C4 "1" stream.
  • the third bottom stream 130 can pass into a fourth gas/liquid separator being a fourth distillation column 54, which provides a fourth gaseous overhead stream 160 (which after cooling can create a "C4" product stream comprising for example >95 mol%, preferably 99 mol%, butanes), and a fourth bottom stream 150 which can be a "C5 "1" " stream, (sometimes also termed a "light condensate” stream) .
  • Figure 2 shows a C2 "1" separation scheme involving a number of separators to provide separate C]_, C2, C3, C4 and C5 “1" streams, which can be provided as direct product streams, or otherwise used in ways known to the person skilled in the art.
  • the initial gaseous overhead stream 110 from the scrub column 34 can pass into a main cryogenic heat exchanger 23 to provide further cooling.
  • the cooling provided by the pre-cooling heat exchangers 46 can be considered as a 'pre-cooling stage', and the cooling provided by the main cryogenic heat exchanger 23 can be considered as a 'main or second cooling stage'.
  • the main cryogenic heat exchanger 23 is typically able to reduce the temperature of the initial gaseous overhead stream 110 to below -90 0 C or -100 0 C, preferably to liquefy the initial gaseous overhead stream 110. Such cooling can be provided in a number of ways known to the person skilled in the art. One example way is use of a refrigerant circuit 25 in a manner known in the art.
  • the main cryogenic heat exchanger 23 provides an overhead stream 120, preferably being fully liquid. Where the initial feed stream 8 is natural gas, the overhead gaseous stream 120 will generally be LNG.
  • the present invention improves the efficiency of the overall LNG plant 2 by reducing the complexity of integration of cooling required of at least one overhead stream with other heat exchangers (such as the pre- cooling heat exchanger 32, 46), or other heat exchanger arrangements .
  • Table 1 gives an overview of estimated compositions, phases, pressures and temperatures of some of the streams at various parts of an example process of Figure 2.
  • the C]_ purity of the first gaseous overhead stream 40 is calculated to be about 94 % for the given mixed hydrocarbon feed stream 10 with a first reboiler duty of first reboiler 17 of 2.6 MW.
  • Table 2 below gives results of a similar calculation as the one for Table 1, with the exception that the warmer second part-feed stream 30b has been fed into the first distillation column 14 at the first tray, the same level as the first part-feed stream 20a.
  • the C]_ purity of the first gaseous overhead stream 40 has decreased to about 90 % for an increase of the first reboiler duty of first reboiler 17 to 2.8 MW.
  • feeding the warmer second part-feed stream 30b into the distillation column 14 at a level below the inlet 38 for the first part-feed stream 20a improves the separation efficiency of the first distillation column 14 while reducing reboiler duty of the first distillation column 14.
  • Suitable process control of embodiments of the present invention may include a level controller on the initial gas/liquid separator 34, which manipulates the flow of the first part-feed stream 20 into the first gas/liquid separator 14, for instance via manipulating the setting of valve 12.
  • Valve 24 may be manipulated using a flow controller, of which the set point is determined by a pressure controller for the second gas/liquid separator. Equivalently, its set point may be determined by a level controller on an optional vessel 21 arranged to receive and discharge the cooled second overhead stream. This is equivalent to pressure control, since the level in the vessel is determined by the duty of the condenser condensation yielding stream 70a.
  • the demonstrated embodiments of the present invention advantageously avoid complicated integration of a NGL removal process with the refrigeration systems of any associated LNG plant or facility.
  • the initial feed stream may be formed of other types of gas, including refinery or petroleum plant gas.

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Abstract

Selon l'invention, un flux d'alimentation condensé d'hydrocarbures mélangés (10), récupéré à partir d'un flux d'alimentation initial (8), est fractionné en un ou plusieurs flux fractionnés. Dans ce processus, le flux d'alimentation condensé d'hydrocarbures mélangés (10) est séparé en au moins un premier flux d'alimentation partiel (20) et en un deuxième flux d'alimentation partiel (30). On fait passer le premier flux d'alimentation partiel (20) dans un premier séparateur gaz/liquide (14) pour obtenir au moins un premier flux fractionné sous forme d'un premier flux de tête gazeux (40). On fait passer un premier flux liquide de fond (50) fourni par le premier séparateur gaz/liquide (14) dans un deuxième séparateur gaz/liquide (22) pour obtenir au moins un deuxième flux fractionné sous forme d'un deuxième flux de tête gazeux (70) qui est refroidi par échange thermique (26) avec le deuxième flux d'alimentation partiel (30).
PCT/EP2008/059383 2007-07-19 2008-07-17 Procédé et dispositif pour récupérer et fractionner un flux d'alimentation d'hydrocarbures mélangés WO2009010558A2 (fr)

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GB0922540A GB2463202B (en) 2007-07-19 2008-07-17 Method and apparatus for producing a liquefied hydrocarbon stream and one or more fractionated streams from an initial feed stream
AU2008277656A AU2008277656B2 (en) 2007-07-19 2008-07-17 Method and apparatus for recovering and fractionating a mixed hydrocarbon feed stream
EA201000224A EA016149B1 (ru) 2007-07-19 2008-07-17 Способ и устройство для выделения и разделения на фракции сырьевого потока смешанных углеводородов
US12/669,073 US20110036120A1 (en) 2007-07-19 2008-07-17 Method and apparatus for recovering and fractionating a mixed hydrocarbon feed stream

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RU2493898C1 (ru) * 2012-06-18 2013-09-27 Открытое акционерное общество "НОВАТЭК" Способ промысловой подготовки продукции газоконденсатных залежей с использованием в качестве хладагента нестабильного газового конденсата и установка для его осуществления
US9021832B2 (en) 2010-01-14 2015-05-05 Ortloff Engineers, Ltd. Hydrocarbon gas processing
EP3115721A1 (fr) 2015-07-10 2017-01-11 Shell Internationale Research Maatschappij B.V. Procédé et système de refroidissement et séparation d'un flux d'hydrocarbure
US10533794B2 (en) 2016-08-26 2020-01-14 Ortloff Engineers, Ltd. Hydrocarbon gas processing
US10551119B2 (en) 2016-08-26 2020-02-04 Ortloff Engineers, Ltd. Hydrocarbon gas processing
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WO2009010558A3 (fr) 2009-11-05
US20110036120A1 (en) 2011-02-17
GB0922540D0 (en) 2010-02-10
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EA016149B1 (ru) 2012-02-28
GB2463202A (en) 2010-03-10

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