WO2011073255A1 - Refrigeration system and method - Google Patents

Refrigeration system and method Download PDF

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Publication number
WO2011073255A1
WO2011073255A1 PCT/EP2010/069756 EP2010069756W WO2011073255A1 WO 2011073255 A1 WO2011073255 A1 WO 2011073255A1 EP 2010069756 W EP2010069756 W EP 2010069756W WO 2011073255 A1 WO2011073255 A1 WO 2011073255A1
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WO
WIPO (PCT)
Prior art keywords
compressor
refrigerant fluid
compressors
turboexpander
directly connected
Prior art date
Application number
PCT/EP2010/069756
Other languages
French (fr)
Inventor
Hans-Gerd Kölscheid
Original Assignee
Siemens Aktiengesellschaft
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Filing date
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Publication of WO2011073255A1 publication Critical patent/WO2011073255A1/en

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Classifications

    • 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
    • F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
    • F25B27/00—Machines, plants or systems, using particular sources of energy
    • 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
    • F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
    • F25B9/00—Compression machines, plants or systems, in which the refrigerant is air or other gas of low boiling point
    • F25B9/06—Compression machines, plants or systems, in which the refrigerant is air or other gas of low boiling point using expanders
    • 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
    • F25J1/005—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 expansion of a gaseous refrigerant stream with extraction of work
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/006—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the refrigerant fluid used
    • F25J1/007—Primary atmospheric gases, mixtures thereof
    • F25J1/0072—Nitrogen
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/02—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
    • F25J1/0203—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
    • F25J1/0204—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 as a single flow SCR cycle
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/02—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process
    • F25J1/0243—Start-up or control of the process; Details of the apparatus used; Details of the refrigerant compression system used
    • F25J1/0279—Compression of refrigerant or internal recycle fluid, e.g. kind of compressor, accumulator, suction drum etc.
    • F25J1/0281—Compression of refrigerant or internal recycle fluid, e.g. kind of compressor, accumulator, suction drum etc. characterised by the type of prime driver, e.g. hot gas expander
    • F25J1/0283—Gas turbine as the prime mechanical driver
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/02—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process
    • F25J1/0243—Start-up or control of the process; Details of the apparatus used; Details of the refrigerant compression system used
    • F25J1/0279—Compression of refrigerant or internal recycle fluid, e.g. kind of compressor, accumulator, suction drum etc.
    • F25J1/0281—Compression of refrigerant or internal recycle fluid, e.g. kind of compressor, accumulator, suction drum etc. characterised by the type of prime driver, e.g. hot gas expander
    • F25J1/0284—Electrical motor as the prime mechanical driver
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/02—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process
    • F25J1/0243—Start-up or control of the process; Details of the apparatus used; Details of the refrigerant compression system used
    • F25J1/0279—Compression of refrigerant or internal recycle fluid, e.g. kind of compressor, accumulator, suction drum etc.
    • F25J1/0285—Combination of different types of drivers mechanically coupled to the same refrigerant compressor, possibly split on multiple compressor casings
    • F25J1/0287—Combination of different types of drivers mechanically coupled to the same refrigerant compressor, possibly split on multiple compressor casings including an electrical motor
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/02—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process
    • F25J1/0243—Start-up or control of the process; Details of the apparatus used; Details of the refrigerant compression system used
    • F25J1/0279—Compression of refrigerant or internal recycle fluid, e.g. kind of compressor, accumulator, suction drum etc.
    • F25J1/0285—Combination of different types of drivers mechanically coupled to the same refrigerant compressor, possibly split on multiple compressor casings
    • F25J1/0288—Combination of different types of drivers mechanically coupled to the same refrigerant compressor, possibly split on multiple compressor casings using work extraction by mechanical coupling of compression and expansion of the refrigerant, so-called companders
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/02—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process
    • F25J1/0243—Start-up or control of the process; Details of the apparatus used; Details of the refrigerant compression system used
    • F25J1/0279—Compression of refrigerant or internal recycle fluid, e.g. kind of compressor, accumulator, suction drum etc.
    • F25J1/0298—Safety aspects and control of the refrigerant compression system, e.g. anti-surge control
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J2220/00—Processes or apparatus involving steps for the removal of impurities
    • F25J2220/60—Separating impurities from natural gas, e.g. mercury, cyclic hydrocarbons
    • F25J2220/64—Separating heavy hydrocarbons, e.g. NGL, LPG, C4+ hydrocarbons or heavy condensates in general
    • 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
    • F25J2230/00—Processes or apparatus involving steps for increasing the pressure of gaseous process streams
    • F25J2230/20—Integrated compressor and process expander; Gear box arrangement; Multiple compressors on a common shaft
    • 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
    • F25J2270/14—External refrigeration with work-producing gas expansion loop
    • F25J2270/16—External refrigeration with work-producing gas expansion loop with mutliple gas expansion loops of the same refrigerant

Definitions

  • Refrigeration system and method relates to a refrigeration system.
  • a refrigeration system may be used, for example, for liquefaction of gaseous hydrocarbon fuels, such as natural gas.
  • gaseous hydrocarbon fuels such as natural gas are liquefied to reduce their volume for easier transportation and storage.
  • the liquefaction involves a refrigeration process, wherein a refrigerant fluid, typically comprising nitrogen especially for smaller liquid natural gas units and floating liquid natural gas systems, is circulated in a refrigeration cycle.
  • a typical refrigeration cycle involves compressing the refrigerant in successive compressor stages, partially cooling the refrigerant at a relatively constant pressure and then expanding the refrigerant in one or more expander stages resulting in a temperature drop of the refrigerant.
  • the cooled refrigerant and the gaseous fuel are passed through a cryogenic heat exchanger, wherein the refrigerant absorbs heat from the gaseous fuel resulting in liquefaction of the gaseous fuel.
  • the refrigerant exiting the heat exchanger is passed back to the compressor stages, whereby the above cycle is repeated.
  • the objective of the present invention is to minimize load on the transmission gear train for refrigeration systems involving geared compressor stages and one or more
  • turboexpanders turboexpanders .
  • the underlying idea of the present invention is to compensate loads on the transmission (i.e., the gear train) of
  • the proposed system includes a plurality of compressors in addition to said first
  • compressor operable for compressing said refrigerant fluid in successive stages of compression
  • turboexpanders operable to expand portions of the refrigerant fluid downstream of said compressors
  • each of said plurality of turboexpanders is directly connected to one of the compressors of said plurality of compressors by a respective shaft, each of said plurality of turboexpanders operable to drive the respective compressor directly connected thereto by a mechanical power output resultant of said expansions, and
  • the proposed system is further characterized in that one or more turboexpanders are operable such that the mechanical power output of each of said one or more turboexpanders balances power consumption by a
  • the proposed system is further characterized in that each compressor and the drive or turboexpander connected thereto are arranged on opposite sides of said transmission gear train.
  • the proposed system is further characterized in that one or more of said turboexpanders comprise inlet guide vanes, said inlet guide vanes being adjustable to regulate flow of the refrigerant fluid through a respective compressor directly connected thereto.
  • said turboexpanders comprise inlet guide vanes, said inlet guide vanes being adjustable to regulate flow of the refrigerant fluid through a respective compressor directly connected thereto.
  • said drive comprises a gas turbine.
  • a starter-helper motor is drivingly coupled to said transmission gear train. The starter-helper motor can be used to facilitate starting of the gas turbine drive and to further boost the rated power output of the gas turbine drive at higher ambient
  • FIG 1 is a block diagram of a refrigeration system involving two compressors and an expander, according to one embodiment of the present invention
  • FIG 2 is a block diagram of a refrigeration system involving three compressors and two expanders, according to another embodiment of the present invention.
  • Embodiments of the present invention provide a refrigeration system involving integrally geared compressors with expander stages used for circulating a refrigerant fluid, wherein the system has an arrangement that results in reduced power transmission and compensation of axial load or thrusts on the gear train.
  • Embodiments of the present invention illustrated below deal with a refrigeration system used in liquefaction of a gaseous hydrocarbon, more particularly, to liquefaction of natural gas.
  • the underlying inventive principle may be used for any other
  • FIG 1 a refrigeration system 1 for circulating a refrigerant fluid, typically comprising nitrogen, in accordance with one embodiment of the present invention.
  • the system 1 includes a plurality of compressors, in this example, a first compressor 2a and a second
  • the compressor 2b includes at least one turboexpander 4a.
  • the first compressor 2a is directly connected to a drive 3 by means of a first shaft 5a.
  • the second compressor 2b is directly connected to the turboexpander 4a by means of a second shaft 5b.
  • the first shaft 5a and the second shaft 5b are drivingly coupled by a transmission gear train 6.
  • the drive 3 provides power to the transmission gear train 6.
  • the drive 3 includes a gas turbine.
  • the drive 3 may include an electrical motor.
  • the compressors 2a and 2b compress a stream 10 of the refrigerant fluid in successive stages of compression.
  • the turboexpander 4a is operated such that the mechanical power output of the turboexpander 4a balances the power consumption of the second compressor 2b, i.e. the power output of the turboexpander 4a and the power consumption of the second compressor 2b are substantially equal. Since the power transmitted by gear train 6 from the second shaft 5b is a difference of the power output of the turboexpander 4a and the power consumed by the second
  • the first compressor 2a and the drive 3 are arranged on opposite sides of the transmission gear train 6, and the second compressor 2b and the expander 4a are arranged on opposite sides of the transmission gear train 6.
  • the above arrangement has the advantage that the axial load or thrust on the gear train 6 by compressors 2a and 2b are respectively compensated by the drive 3 and the turboexpander 4a.
  • a starter-helper motor 9 is drivingly coupled to the gear train 6.
  • the starter-helper motor 9 can be used to facilitate starting of the gas turbine 3 and to further boost the rated power output of the gas turbine 3 at higher ambient temperatures
  • the turboexpander 4a includes adjustable inlet guide vanes 8c to control power output of the turboexpander 4a, and, in turn, the flow of refrigerant fluid through the second compressor 2b.
  • the flow of refrigerant fluid through the first compressor 2a may be controlled by adjustable inlet guide vanes 8c provided on the suction end of the compressor 2a.
  • the inlet guide vanes 8a and 8c may
  • refrigerant fluid is compressed in a first stage of
  • the compressed stream 10a of the refrigerant fluid flowing out of the first compressor 2a is cooled by a first aftercooler 7a and a cooled stream 10b of the refrigerant fluid is further compressed in a second stage of compression by the second compressor 2b.
  • the compressed refrigerant fluid 10c flowing out of the second compressor 2b is optionally cooled by a second aftercooler 7b.
  • the refrigerant fluid stream lOg flowing out of the aftercooler 7b is partially cooled in a heat exchanger 11, against a low temperature, low pressure returning stream lOj of the refrigerant fluid.
  • the partially cooled refrigerant fluid stream lOi is expanded by the turboexpander 4a, resulting in a drop in temperature and pressure of the refrigerant fluid.
  • expansion of the refrigerant fluid by the turboexpander 4a produces mechanical power, which is transmitted to the second compressor 2b through the shaft 5b.
  • the refrigerant fluid stream lOj exiting the expander at low temperature and pressure is passed to the heat exchanger 11, wherein it absorbs heat from the stream lOg of refrigerant fluid
  • a stream 13 of natural gas is passed through the heat exchanger 11, wherein it is cooled and subsequently liquefied by heat transfer to the
  • refrigerant fluid stream lOj refrigerant fluid stream lOj .
  • liquefaction may be achieved by cooling the stream 13 of natural gas over multiple stages.
  • the precooled gas 13b (mainly methane) is passed again into heat exchanger 11 for a further stage of cooling via heat transfer to the refrigerant stream
  • the present invention may also be used for refrigeration systems having more than two compressors, and multiple turboexpanders , for increased refrigerating capacity.
  • the first compressor stage may be directly connected to the drive by a shaft, and each of the other compressors directly connected to a respective turboexpander via separate shafts, the shafts being drivingly coupled by a transmission gear train.
  • FIG 2 illustrates an example of a refrigeration system 1 having three compressors 2a, 2b and 2c and two expanders 4a and 4b. The arrangement of the compressors 2a and 2b with respect to the drive 3 and the first
  • turboexpander 4a are similar to that of the earlier mentioned embodiment (FIG 1) . Additionally herein (FIG 2), a third compressor 2c is directly connected to a second turboexpander 4b by a third shaft 5c.
  • the shafts 5a, 5b and 5c are
  • each of the turboexpanders 4a and 4b is operated such that their
  • turboexpander/drive are arranged on opposite sides of the transmission gear train 6 for compensation of axial load or thrusts on the gear train 6.
  • refrigerant fluid flow and hence the refrigerating capacity of the system 1 may be regulated by controlling, individually or in combination, adjustable inlet guide vanes 8a, 8b and 8c provided respectively on the inlets of the turboexpanders 4a and 4b and the compressor 2a.
  • a stream 10 of the refrigerant fluid is compressed in a first stage of
  • the compressed stream 10a of the refrigerant fluid flowing out of the first compressor 2a is cooled by a first aftercooler 7a and a cooled stream 10b of the refrigerant fluid is further compressed in a second stage of compression by the second compressor 2b.
  • the compressed refrigerant fluid 10c flowing out of the second compressor 2b is optionally cooled by a second aftercooler 7b.
  • the refrigerant fluid stream lOd flowing out of the aftercooler 7b is further compressed in a third stage of compression by the third compressor 2c.
  • the compressed refrigerant fluid lOe flowing out of the third compressor 2c is optionally cooled by a third aftercooler 7c.
  • the refrigerant fluid stream lOf flowing out of the third aftercooler 7c is divided into two stream portions lOg and lOh and passed into the heat exchanger 11.
  • the first divided stream lOg is partially cooled in the heat exchanger 11 against a low temperature, low pressure returning stream 10 ⁇ of the refrigerant fluid.
  • the stream lOg exits the heat exchanger as a partially cooled refrigerant stream lOi, which is expanded by the turboexpander 4a to result in a drop in temperature and pressure of the refrigerant.
  • the second divided stream lOh is further cooled in the heat exchanger 11 against the low temperature, low pressure returning stream 10 ⁇ of the refrigerant fluid.
  • the stream lOh exits the heat exchanger as a further cooled refrigerant stream 10k, which is expanded by the turboexpander 4b to result in a further drop in temperature and pressure of the refrigerant.
  • the refrigerant streams lOj and 101 exiting the turboexpanders 4a and 4b respectively are then merged into a low temperature, low pressure refrigerant stream in the heat exchanger 11, which is further used to for liquefaction of a stream 13 of natural gas described above.

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

Abstract

A refrigeration system (1) for circulating a refrigerant fluid (10) comprises a first compressor (2a) and a second compressor (2b) operable to compress said refrigerant fluid (10) in separate stages of compression and at least one turboexpander (4a) operable to expand at least a portion (10i) of the refrigerant fluid downstream of said compressors (2a, 2b). In accordance with the present invention, a drive (3) is directly connected to the first compressor (2a) by a first shaft (5a), the turboexpander (4a) is directly connected to the second compressor (2b) by a second shaft (5b) and is operable to drive the second compressor (2b) by a mechanical power output resultant from said expansion and the first shaft (5a) is drivingly coupled to the second shaft (5b) by a transmission gear train (6).

Description

Description
Refrigeration system and method The present invention relates to a refrigeration system. Such a system may be used, for example, for liquefaction of gaseous hydrocarbon fuels, such as natural gas.
Generally, gaseous hydrocarbon fuels, such as natural gas are liquefied to reduce their volume for easier transportation and storage. The liquefaction involves a refrigeration process, wherein a refrigerant fluid, typically comprising nitrogen especially for smaller liquid natural gas units and floating liquid natural gas systems, is circulated in a refrigeration cycle. A typical refrigeration cycle involves compressing the refrigerant in successive compressor stages, partially cooling the refrigerant at a relatively constant pressure and then expanding the refrigerant in one or more expander stages resulting in a temperature drop of the refrigerant. The cooled refrigerant and the gaseous fuel are passed through a cryogenic heat exchanger, wherein the refrigerant absorbs heat from the gaseous fuel resulting in liquefaction of the gaseous fuel. The refrigerant exiting the heat exchanger is passed back to the compressor stages, whereby the above cycle is repeated.
Some existing refrigeration systems are known to use
integrally geared compressor stages for successive
compression of the refrigerant, along with turboexpanders for expanding the refrigerant. However, in such systems, the axial load or thrust on the transmission gear train lead to increased vibration of the transmission gear train, loss of power and a reduction in overall efficiency of the system. Further, since the axial load or thrust increases with increase in the number of compressor stages, this leads to a limitation of the total number compressor stages, thus limiting the refrigerating capacity of the system. The objective of the present invention is to minimize load on the transmission gear train for refrigeration systems involving geared compressor stages and one or more
turboexpanders .
The above object is achieved by the system according to claim 1 and the method according to claim 9.
The underlying idea of the present invention is to compensate loads on the transmission (i.e., the gear train) of
integrally geared compressor stages by directly connecting one of the compressors to the drive and directly connecting one or more other compressor to a respective turboexpander . This has the advantage that power consumption of a compressor and the power output of the respective turboexpander
connected thereto now compensate each other, so that the transmission has to transmit only the difference. This leads to reduced power loss and greater overall efficiency of the system.
In one example embodiment, the proposed system includes a plurality of compressors in addition to said first
compressor, operable for compressing said refrigerant fluid in successive stages of compression, and a plurality of turboexpanders operable to expand portions of the refrigerant fluid downstream of said compressors, said system further characterized in that
- each of said plurality of turboexpanders is directly connected to one of the compressors of said plurality of compressors by a respective shaft, each of said plurality of turboexpanders operable to drive the respective compressor directly connected thereto by a mechanical power output resultant of said expansions, and
- said shafts are drivingly coupled by the transmission gear train. Thus any number of compressor trains can be used for increase in the refrigerating capacity of the system, without a substantial increase in load on the transmission, due to the power compensation as mentioned above. In an advantageous embodiment, the proposed system is further characterized in that one or more turboexpanders are operable such that the mechanical power output of each of said one or more turboexpanders balances power consumption by a
respective compressor directly connected thereto. This leads to a further reduction in the power transmitted by the transmission, which reduces mechanical load on the
transmission .
In a preferred embodiment, to further compensate axial load or thrust on the transmission, the proposed system is further characterized in that each compressor and the drive or turboexpander connected thereto are arranged on opposite sides of said transmission gear train.
In a preferred embodiment, the proposed system is further characterized in that one or more of said turboexpanders comprise inlet guide vanes, said inlet guide vanes being adjustable to regulate flow of the refrigerant fluid through a respective compressor directly connected thereto. This provides simplicity to the refrigeration process wherein the refrigerating capacity of the system can be regulated by adjusting the inlet guide vanes, obviating the need for cut- off valves and complicated piping.
In an exemplary embodiment, said drive comprises a gas turbine. In a further embodiment, a starter-helper motor is drivingly coupled to said transmission gear train. The starter-helper motor can be used to facilitate starting of the gas turbine drive and to further boost the rated power output of the gas turbine drive at higher ambient
temperatures prevailing at most gas liquefaction plants. The present invention is further described hereinafter with reference to illustrated embodiments shown in the
accompanying drawings, in which: FIG 1 is a block diagram of a refrigeration system involving two compressors and an expander, according to one embodiment of the present invention, and FIG 2 is a block diagram of a refrigeration system involving three compressors and two expanders, according to another embodiment of the present invention.
Embodiments of the present invention provide a refrigeration system involving integrally geared compressors with expander stages used for circulating a refrigerant fluid, wherein the system has an arrangement that results in reduced power transmission and compensation of axial load or thrusts on the gear train. Embodiments of the present invention illustrated below deal with a refrigeration system used in liquefaction of a gaseous hydrocarbon, more particularly, to liquefaction of natural gas. However, it is to be understood that the underlying inventive principle may used for any other
application .
Referring now to FIG 1 is illustrated a refrigeration system 1 for circulating a refrigerant fluid, typically comprising nitrogen, in accordance with one embodiment of the present invention. The system 1 includes a plurality of compressors, in this example, a first compressor 2a and a second
compressor 2b, and includes at least one turboexpander 4a. The first compressor 2a is directly connected to a drive 3 by means of a first shaft 5a. The second compressor 2b is directly connected to the turboexpander 4a by means of a second shaft 5b. The first shaft 5a and the second shaft 5b are drivingly coupled by a transmission gear train 6. The drive 3 provides power to the transmission gear train 6. In the illustrated embodiment, the drive 3 includes a gas turbine. Alternately, the drive 3 may include an electrical motor. The compressors 2a and 2b compress a stream 10 of the refrigerant fluid in successive stages of compression.
Downstream of the compressors 2a and 2b, a stream lOi of the refrigerant fluid is partially cooled and subsequently expanded by the turboexpander 4a, which resultantly produces a mechanical power output, which, in turn, is used to drive the second compressor 2b connected to the turboexpander 4a. The proposed arrangement has the advantage that power
consumption of the compressor 2b and the power output of the turboexpander 4a now compensate each other, so that the gear train 6 has to transmit only the difference. This leads to reduced power loss and greater overall efficiency of the system 1.
In a preferred embodiment, the turboexpander 4a is operated such that the mechanical power output of the turboexpander 4a balances the power consumption of the second compressor 2b, i.e. the power output of the turboexpander 4a and the power consumption of the second compressor 2b are substantially equal. Since the power transmitted by gear train 6 from the second shaft 5b is a difference of the power output of the turboexpander 4a and the power consumed by the second
compressor 2b, the above arrangement leads to a significant reduction in the power transmitted by the gear train 6, which reduces mechanical load on the gear train 6. Further
preferably, as shown, the first compressor 2a and the drive 3 are arranged on opposite sides of the transmission gear train 6, and the second compressor 2b and the expander 4a are arranged on opposite sides of the transmission gear train 6. The above arrangement has the advantage that the axial load or thrust on the gear train 6 by compressors 2a and 2b are respectively compensated by the drive 3 and the turboexpander 4a.
In the illustrated embodiment, a starter-helper motor 9 is drivingly coupled to the gear train 6. Advantageously, the starter-helper motor 9 can be used to facilitate starting of the gas turbine 3 and to further boost the rated power output of the gas turbine 3 at higher ambient temperatures
prevailing at most gas liquefaction plants. In an advantageous embodiment of the present invention, the turboexpander 4a includes adjustable inlet guide vanes 8c to control power output of the turboexpander 4a, and, in turn, the flow of refrigerant fluid through the second compressor 2b. Also, the flow of refrigerant fluid through the first compressor 2a may be controlled by adjustable inlet guide vanes 8c provided on the suction end of the compressor 2a. Advantageously, the inlet guide vanes 8a and 8c may
controlled, individually, or in combination for regulating the refrigerant flow rate through the compressors and hence, the regulating the refrigerating capacity of the system 1. This provides simplicity to the refrigeration process
obviating the need for cut-off valves and complicated piping. Referring to FIG 1, in operation, a stream 10 of the
refrigerant fluid is compressed in a first stage of
compression by the first compressors 2a. Optionally, the compressed stream 10a of the refrigerant fluid flowing out of the first compressor 2a is cooled by a first aftercooler 7a and a cooled stream 10b of the refrigerant fluid is further compressed in a second stage of compression by the second compressor 2b. The compressed refrigerant fluid 10c flowing out of the second compressor 2b is optionally cooled by a second aftercooler 7b. The refrigerant fluid stream lOg flowing out of the aftercooler 7b is partially cooled in a heat exchanger 11, against a low temperature, low pressure returning stream lOj of the refrigerant fluid. The partially cooled refrigerant fluid stream lOi is expanded by the turboexpander 4a, resulting in a drop in temperature and pressure of the refrigerant fluid. As mentioned earlier, expansion of the refrigerant fluid by the turboexpander 4a produces mechanical power, which is transmitted to the second compressor 2b through the shaft 5b. The refrigerant fluid stream lOj exiting the expander at low temperature and pressure is passed to the heat exchanger 11, wherein it absorbs heat from the stream lOg of refrigerant fluid
downstream of the compressor stages to partially cool the refrigerant fluid prior to expansion by the turboexpander 4a. For liquefaction of natural gas, a stream 13 of natural gas is passed through the heat exchanger 11, wherein it is cooled and subsequently liquefied by heat transfer to the
refrigerant fluid stream lOj . Although not explicitly shown, liquefaction may be achieved by cooling the stream 13 of natural gas over multiple stages.
In this example a gas/liquid stream 13a of natural gas coming from the heat exchanger 11 is passed into the separator 12. A separation device 14 separates gas 13b and liquid 13d
(heavy hydro carbons) . The precooled gas 13b (mainly methane) is passed again into heat exchanger 11 for a further stage of cooling via heat transfer to the refrigerant stream
lOj, whereby a stream of liquefied natural gas (13C) exits the heat exchanger 11, which may be subsequently passed to a storage tank (not shown) . The gaseous components are
submitted to a flare connection 13e. The refrigerant stream 10 exiting the heat exchanger 11 re-enters the first stage compressor 2a and the above cycle is repeated.
The present invention may also be used for refrigeration systems having more than two compressors, and multiple turboexpanders , for increased refrigerating capacity. In such a case, the first compressor stage may be directly connected to the drive by a shaft, and each of the other compressors directly connected to a respective turboexpander via separate shafts, the shafts being drivingly coupled by a transmission gear train. FIG 2 illustrates an example of a refrigeration system 1 having three compressors 2a, 2b and 2c and two expanders 4a and 4b. The arrangement of the compressors 2a and 2b with respect to the drive 3 and the first
turboexpander 4a are similar to that of the earlier mentioned embodiment (FIG 1) . Additionally herein (FIG 2), a third compressor 2c is directly connected to a second turboexpander 4b by a third shaft 5c. The shafts 5a, 5b and 5c are
drivingly coupled by the gear train 6. Herein the power consumptions by the compressors 2b and 2c and the power outputs of the turboexpanders 4a and 4b respectively
compensate each other, leading to reduced load on the gear train 6. Further in a preferred embodiment, each of the turboexpanders 4a and 4b is operated such that their
mechanical power output balance (i.e., are substantially equal to) the power consumption of the respective compressors 2b and 2c, thereby significantly reducing the power to be transmitted by the gear train 6. Further preferably, as shown, each of the compressors and the corresponding
turboexpander/drive are arranged on opposite sides of the transmission gear train 6 for compensation of axial load or thrusts on the gear train 6. Further, similar to the earlier illustrated embodiment, refrigerant fluid flow and hence the refrigerating capacity of the system 1 may be regulated by controlling, individually or in combination, adjustable inlet guide vanes 8a, 8b and 8c provided respectively on the inlets of the turboexpanders 4a and 4b and the compressor 2a.
In operation of the system 1 of FIG 2, a stream 10 of the refrigerant fluid is compressed in a first stage of
compression by the first compressors 2a. Optionally, the compressed stream 10a of the refrigerant fluid flowing out of the first compressor 2a is cooled by a first aftercooler 7a and a cooled stream 10b of the refrigerant fluid is further compressed in a second stage of compression by the second compressor 2b. The compressed refrigerant fluid 10c flowing out of the second compressor 2b is optionally cooled by a second aftercooler 7b. The refrigerant fluid stream lOd flowing out of the aftercooler 7b is further compressed in a third stage of compression by the third compressor 2c. The compressed refrigerant fluid lOe flowing out of the third compressor 2c is optionally cooled by a third aftercooler 7c. The refrigerant fluid stream lOf flowing out of the third aftercooler 7c is divided into two stream portions lOg and lOh and passed into the heat exchanger 11. The first divided stream lOg is partially cooled in the heat exchanger 11 against a low temperature, low pressure returning stream 10η of the refrigerant fluid. The stream lOg exits the heat exchanger as a partially cooled refrigerant stream lOi, which is expanded by the turboexpander 4a to result in a drop in temperature and pressure of the refrigerant. The second divided stream lOh is further cooled in the heat exchanger 11 against the low temperature, low pressure returning stream 10η of the refrigerant fluid. The stream lOh exits the heat exchanger as a further cooled refrigerant stream 10k, which is expanded by the turboexpander 4b to result in a further drop in temperature and pressure of the refrigerant. The refrigerant streams lOj and 101 exiting the turboexpanders 4a and 4b respectively are then merged into a low temperature, low pressure refrigerant stream in the heat exchanger 11, which is further used to for liquefaction of a stream 13 of natural gas described above.
Although the invention has been described with reference to specific embodiments, this description is not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments, as well as alternate embodiments of the invention, will become apparent to persons skilled in the art upon reference to the description of the invention. For example, it may be appreciated by one skilled in the art that embodiments of the present invention may also include
refrigeration systems having more than three compressors and more than two turboexpanders, as may be necessary, for example, for providing a required refrigerating capacity. It is therefore contemplated that all such embodiments are within the scope of the present invention as defined by the below-mentioned patent claims.

Claims

Patent claims
1. A refrigeration system (1) for circulating a refrigerant fluid (10) , comprising a first compressor (2a) and a second compressor (2b) operable to compress said refrigerant
fluid (10) in separate stages of compression and at least one turboexpander (4a) operable to expand at least a
portion (lOi) of the refrigerant fluid downstream of said compressors (2a, 2b), the system (1) wherein:
- a drive (3) is directly connected to the first
compressor (2a) by a first shaft (5a) ,
- the turboexpander (4a) is directly connected to the second compressor (2b) by a second shaft (5b) and is operable to drive the second compressor (2b) by a mechanical power output resultant from said expansion, and
- the first shaft (5a) is drivingly coupled to the second shaft (5b) by a transmission gear train (6) ,
- wherein said turboexpanders (4a, 4b) comprise inlet guide vanes (8a, 8b), said inlet guide vanes (8a) being adjustable to regulate flow of the refrigerant fluid through a
respective compressor (2b, 2c) directly connected thereto.
2. The system (1) according any of the preceding claims, comprising a plurality of compressors (2b, 2c) in addition to said first compressor (2a) , operable for compressing said refrigerant fluid (10) in separate stages of compression, and a plurality of turboexpanders (4a, 4b) operable to expand portions (10i,10k) of the refrigerant fluid downstream of said compressors (2a, 2b, 2c), said system (1) further
characterized in that
- each of said plurality of turboexpanders (4a, 4b) is
directly connected to one of the compressors (2b, 2c) of said plurality of compressors (2b, 2c) by a respective
shaft (5b, 5c), each of said plurality of
turboexpanders (4a, 4b) operable to drive the respective compressor (2b, 2c) directly connected thereto by a mechanical power output resultant of said expansions, and - said shafts (5a, 5b, 5c) are drivingly coupled by the
transmission gear train (6) .
3. The system (1) according to any of the preceding claims, further characterized in that one or more
turboexpanders (4a, 4b) are operable such that the mechanical power output of each of said one or more
turboexpanders (4a, 4b) balances power consumption by a respective compressor (2b, 2c) directly connected thereto.
4. The system (1) according to any of the preceding claims, further characterized in that each compressor (2a, 2b, 2c) and the drive (3) or turboexpander (4a, 4b) connected thereto are arranged on opposite sides of said transmission gear
train (6) .
5. The system (1) according to any of the preceding claims, wherein said drive (3) comprises a gas turbine.
6. The system (1) according to claim 5, further comprising a starter-helper motor (9) drivingly coupled to said
transmission gear train (6) .
7. The system (1) according to any of the preceding claims, further comprising a heat exchanger (11) for engaging heat transfer between a portion (lOj) of the refrigerant fluid expanded by said at least one turboexpander (4a) and at least a portion (lOg) of the refrigerant fluid compressed by said compressors, to partially cool said portion (lOg) of the refrigerant fluid compressed by said compressors prior to expansion by said at least one turboexpander (4a) .
8. A refrigeration method involving circulation a refrigerant fluid (10) , comprising operating a first compressor (2a) and a second compressor (2b) to compress said refrigerant
fluid (10) in separate stages of compression and operating at least one turboexpander (4a) to expand at least a portion (lOi) of the refrigerant fluid downstream of said compressors (2a, 2b), said method characterized by
- driving the first compressor (2a) by a drive (3) directly connected the first compressor (2a) by a first shaft (5a) , and
- driving the second compressor (2b) by a mechanical power output from the turboexpander (4a) resulting from said expansion, wherein the turboexpander (4a) is directly
connected to the second compressor (2b) by a second
shaft (5b) , the second shaft (5b) being drivingly coupled to the first shaft (5a) by a transmission gear train .(6) .
9. The method according to claim 8, comprising operating a plurality of compressors (2b, 2c) in addition to said first compressor (2a) for compressing said refrigerant fluid (10) in separate stages of compression, and operating a plurality of turboexpanders (4a, 4b) to expand portions (10i,10k) of the refrigerant fluid downstream of said compressors (2a, 2b, 2c), said method further, wherein:
- driving each of said plurality of compressors (2b, 2c) by a mechanical power output of a respective turboexpander (4a, 4b) directly connected thereto by a respective shaft (5b, 5c), the mechanical power output of said turboexpanders (4a, 4b) resultant from said expansions, wherein said
shafts (5a, 5b, 5c) are drivingly coupled by the transmission gear train (6)
- regulating flow through one or more compressors (2b, 2c) by adjusting inlet guide vanes (8a, 8b) of a respective
turboexpander (4a, 4b) directly connected thereto.
10. The method according to any of claims 8 and 9, further characterized by operating one or more turboexpanders (4a, 4b) such that the mechanical power output of each of said one or more turboexpanders (4a, 4b) balances power consumption by a respective compressor (2b, 2c) directly connected thereto.
11. The method according to any of claims 9 to 10, wherein each compressor (2a, 2b, 2c) and the drive (3) or
turboexpander (4a, 4b) connected thereto are arranged on opposite sides of said transmission gear train (6) .
12. The method according to any of claims 8 to 11, comprising operating a gas turbine as said drive (3) .
13. The method according to claim 12, further comprising operating a starter-helper motor (9) drivingly coupled to said transmission gear train (6) .
PCT/EP2010/069756 2009-12-15 2010-12-15 Refrigeration system and method WO2011073255A1 (en)

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