WO2011135335A2 - Procédé et appareil de liquéfaction de gaz naturel - Google Patents

Procédé et appareil de liquéfaction de gaz naturel Download PDF

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Publication number
WO2011135335A2
WO2011135335A2 PCT/GB2011/050779 GB2011050779W WO2011135335A2 WO 2011135335 A2 WO2011135335 A2 WO 2011135335A2 GB 2011050779 W GB2011050779 W GB 2011050779W WO 2011135335 A2 WO2011135335 A2 WO 2011135335A2
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WO
WIPO (PCT)
Prior art keywords
refrigerant
natural gas
cooled
heat exchange
liquefaction
Prior art date
Application number
PCT/GB2011/050779
Other languages
English (en)
Other versions
WO2011135335A3 (fr
Inventor
Grant Johnson
Timothy Eastwood
Original Assignee
Costain Oil, Gas & Process Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Costain Oil, Gas & Process Limited filed Critical Costain Oil, Gas & Process Limited
Priority to AU2011247081A priority Critical patent/AU2011247081B2/en
Priority to EP11717717.0A priority patent/EP2564139B1/fr
Publication of WO2011135335A2 publication Critical patent/WO2011135335A2/fr
Publication of WO2011135335A3 publication Critical patent/WO2011135335A3/fr

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    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/0002Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the fluid to be liquefied
    • F25J1/0022Hydrocarbons, e.g. natural gas
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/003Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the kind of cold generation within the liquefaction unit for compensating heat leaks and liquid production
    • F25J1/0032Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the kind of cold generation within the liquefaction unit for compensating heat leaks and liquid production using the feed stream itself or separated fractions from it, i.e. "internal refrigeration"
    • F25J1/0035Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the kind of cold generation within the liquefaction unit for compensating heat leaks and liquid production using the feed stream itself or separated fractions from it, i.e. "internal refrigeration" by gas expansion with extraction of work
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/003Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the kind of cold generation within the liquefaction unit for compensating heat leaks and liquid production
    • F25J1/0032Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the kind of cold generation within the liquefaction unit for compensating heat leaks and liquid production using the feed stream itself or separated fractions from it, i.e. "internal refrigeration"
    • F25J1/0035Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the kind of cold generation within the liquefaction unit for compensating heat leaks and liquid production using the feed stream itself or separated fractions from it, i.e. "internal refrigeration" by gas expansion with extraction of work
    • F25J1/0037Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the kind of cold generation within the liquefaction unit for compensating heat leaks and liquid production using the feed stream itself or separated fractions from it, i.e. "internal refrigeration" by gas expansion with extraction of work of a return stream
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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    • F25J1/00Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
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    • F25J1/0047Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the kind of cold generation within the liquefaction unit for compensating heat leaks and liquid production using an "external" refrigerant stream in a closed vapor compression cycle
    • F25J1/005Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the kind of cold generation within the liquefaction unit for compensating heat leaks and liquid production using an "external" refrigerant stream in a closed vapor compression cycle by expansion of a gaseous refrigerant stream with extraction of work
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    • F25J1/007Primary atmospheric gases, mixtures thereof
    • F25J1/0072Nitrogen
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    • F25J1/006Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the refrigerant fluid used
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    • F25J1/0082Methane
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    • F25J1/0097Others, e.g. F-, Cl-, HF-, HClF-, HCl-hydrocarbons etc. or mixtures thereof
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    • F25J3/063Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by partial condensation characterised by the separated product stream
    • F25J3/0635Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by partial condensation characterised by the separated product stream separation of CnHm with 1 carbon atom or more
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J3/00Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification
    • F25J3/06Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by partial condensation
    • F25J3/063Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by partial condensation characterised by the separated product stream
    • F25J3/064Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by partial condensation characterised by the separated product stream separation of CnHm with 2 carbon atoms or more
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J2220/00Processes or apparatus involving steps for the removal of impurities
    • F25J2220/60Separating impurities from natural gas, e.g. mercury, cyclic hydrocarbons
    • F25J2220/62Separating low boiling components, e.g. He, H2, N2, Air
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J2230/00Processes or apparatus involving steps for increasing the pressure of gaseous process streams
    • F25J2230/20Integrated compressor and process expander; Gear box arrangement; Multiple compressors on a common shaft
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J2230/00Processes or apparatus involving steps for increasing the pressure of gaseous process streams
    • F25J2230/30Compression of the feed stream
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J2240/00Processes or apparatus involving steps for expanding of process streams
    • F25J2240/02Expansion of a process fluid in a work-extracting turbine (i.e. isentropic expansion), e.g. of the feed stream
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J2240/00Processes or apparatus involving steps for expanding of process streams
    • F25J2240/40Expansion without extracting work, i.e. isenthalpic throttling, e.g. JT valve, regulating valve or venturi, or isentropic nozzle, e.g. Laval
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J2270/00Refrigeration techniques used
    • F25J2270/14External refrigeration with work-producing gas expansion loop
    • F25J2270/16External refrigeration with work-producing gas expansion loop with mutliple gas expansion loops of the same refrigerant

Definitions

  • This invention relates to processes and apparatus for the liquefaction of natural gas.
  • the invention relates to processes and apparatus in which expansion of a refrigerant through a turbo-expander as part of a refrigeration cycle is used to drive a compressor which increases the pressure of the natural gas feed to the liquefaction process.
  • Natural gas fields are often located at large distances from consumer markets and effective and economical methods for the transportation of natural gas are an important aspect of the natural gas industry.
  • the majority of natural gas is transported by pipelines, and pipeline networks are well-established in Europe, North America and the former Soviet Union.
  • pipelines are costly to construct and are not economically viable for transporting gas from remote gas fields. Liquefaction of natural gas is therefore an important technology in enabling the exploitation of remote gas fields and the supply of natural gas to markets that are not adequately served by pipeline gas supplies.
  • Liquefied natural gas has approximately 1/600 the volume of natural gas in the gaseous state.
  • the reduction in volume makes the transportation of natural gas over large distances much more economical, for example using specially designed cryogenic sea vessels (LNG carriers) or cryogenic road tankers.
  • Processes for the liquefaction of natural gas involve condensing the natural gas to produce a liquid at or around atmospheric pressure.
  • the natural gas fed to liquefaction processes typically comprises greater than 80% methane together with small amounts of ethane, propane and butane.
  • Heavier hydrocarbons, such as pentane, hexane and benzene, which freeze above the temperature of liquefied natural gas (approximately -162 °C at atmospheric pressure) are usually removed from the natural gas feed by upstream processing, together with other impurities such as water and carbon dioxide which also freeze.
  • the use of turbo-expander refrigeration cycles is well established in the production of liquefied natural gas.
  • turbo-expander is used to refer to a radial or axial flow turbine through which a pressurised gas is expanded to produce work.
  • the work extracted from the expanding pressurised gas may be used to drive a compressor or generator.
  • Expansion using turbo-expanders is a near isentropic process resulting in a low temperature expanded gas which is used to provide refrigeration in many industrial processes.
  • turbo-expander based liquefaction cycles have found use mainly in small-scale plants producing up to approximately 0.1 million tonnes LNG per annum.
  • vapour-compression refrigeration cycles employing mixed hydrocarbon refrigerants or cascaded refrigerants predominate, primarily due to their high thermodynamic efficiency / low power requirements.
  • Turbo-expander cycles have been used at high production capacities for sub-cooling of LNG due to their high thermodynamic efficiency over this low temperature range.
  • Liquefaction feed gas 400 is fed to a multi-stream liquefaction heat exchanger 505 where it is condensed and sub-cooled against multiple nitrogen refrigerant streams, exiting the heat exchanger 505 as a sub-cooled liquid 425.
  • Sub- cooled liquid 425 is let down to storage pressure across valve 430 to give a two-phase stream 435, which passes to a vapour-liquid separator 440 to separate a low pressure LNG product stream 450 for storage and a flash gas stream 445.
  • Refrigeration to produce the LNG product stream is provided by a dual nitrogen turbo- expander refrigeration cycle.
  • Nitrogen is compressed in a two-stage cycle compressor 580/590, incorporating inter- and after-coolers 575/585/595 (typically against air or water) to produce a high-pressure nitrogen stream 500.
  • High-pressure nitrogen stream 500 is split between warm and cold turbo-expander cycles.
  • Warm nitrogen cycle feed gas is cooled in the liquefaction heat exchanger 505 to produce a cooled nitrogen cycle gas stream 510 at an intermediate temperature by heat exchange with returning cold low-pressure nitrogen cycle gas 520/535.
  • the resulting cooled nitrogen cycle gas 510 is work-expanded in a warm cycle turbo-expander 515 to give a cold low-pressure nitrogen cycle gas 520 and to drive the warm cycle brake compressor 545.
  • Cold low pressure nitrogen cycle gas 520 is reheated in liquefaction heat exchanger 505, cooling the warm and cold nitrogen cycle feed gas streams and cooling, condensing and sub-cooling the natural gas stream 400.
  • the reheated warm cycle low-pressure nitrogen gas stream 540 is fed to the warm cycle turbo-expander brake compressor 545, driven by the warm cycle turbo-expander 515.
  • Cold nitrogen cycle feed gas is cooled in the liquefaction heat exchanger 505 to produce a cooled nitrogen cycle gas stream 525 at a temperature approaching that of the warm cycle turbo-expander discharge stream 520 by heat exchange with returning cold low- pressure nitrogen cycle gas 520/535.
  • Cooled nitrogen cycle gas 525 is work-expanded in a cold cycle turbo-expander 530 to form a cold low-pressure nitrogen stream 535 and to drive cold cycle brake compressor 560.
  • Cold low-pressure nitrogen cycle gas 535 has a pressure similar to that of the warm expander discharge stream 520 and is reheated in the liquefaction heat exchanger 505, cooling the warm and cold nitrogen cycle feed gas streams and cooling, condensing and sub-cooling the natural gas stream 400.
  • the reheated warm cycle low-pressure nitrogen gas stream 555 is fed to the cold cycle turbo- expander brake compressor 560, driven by the cold cycle turbo-expander 530.
  • the compressed reheated warm and cold cycle nitrogen gas streams 550/565 are fed to the cycle compressors 585/595 for compression.
  • Liquefaction process thermodynamic efficiency is normally expressed as specific power consumption - for example kWh/kg LNG produced.
  • Reduced specific power consumption can translate either to: (i) lower power consumption for a given capacity; or (ii) higher capacity for a given power consumption. The latter can be of significant benefit to project economics if power is constrained by the output of a particular compressor driver or a particular power generation configuration.
  • low temperature cooling water e.g. sea water drawn from deep water or chilled water from a refrigeration unit
  • Low feed pressure to the liquefaction plant may be a consequence of a low field reservoir pressure or may result from upstream processing for extraction of heavy hydrocarbons and other impurities.
  • the removal of heavy hydrocarbons and other impurities is usually required to prevent solidification of these components during the liquefaction process.
  • deeper hydrocarbon removal is also used to recover a saleable liquid petroleum gas (LPG) product comprising C3 and C4 hydrocarbons in addition to a condensate product to increase revenue, or to adjust LNG composition to meet gas quality specifications.
  • LPG saleable liquid petroleum gas
  • this invention provides a process for liquefaction of natural gas comprising the steps of: (a) providing a first refrigeration cycle comprising the steps of:
  • step (ii) cooling the compressed refrigerant from step (i) in heat exchange with a cooling fluid to provide a cooled compressed refrigerant;
  • step (iii) work-expanding at least a first portion of the cooled compressed refrigerant from step (ii) in a first turbo-expander to provide an expanded cooled refrigerant;
  • step (v) returning the reheated refrigerant from step (iv) to step (i);
  • step (c) withdrawing a cooled and at least partly condensed natural gas product from the liquefaction heat exchange system; wherein the first turbo-expander is used to drive a compressor to compress the natural gas feed stream in step (c).
  • Power input to the process is provided by compression of the fluid refrigerant in step (i), and heat is removed from the refrigeration cycle by heat exchange between the refrigerant and a cooling fluid in step (ii).
  • Any suitable cooling fluid may be used, for instance, water or air.
  • sea water may be a suitable cooling fluid for use with offshore processes or for onshore processing plants which are conventionally located close to the sea.
  • the compressed natural gas stream is fully condensed and sub-cooled in step (d).
  • the process of the present invention is not limited to refrigeration cycles using one turbo- expander.
  • double turbo expander refrigeration cycles may be used.
  • the first refrigeration cycle further comprises the steps of: (vi) expanding a second portion of the cooled compressed refrigerant from step (ii); (vii) passing the expanded cooled refrigerant from step (vi) to the liquefaction heat exchange system to provide a reheated refrigerant; and
  • step (viii) returning the reheated refrigerants from steps (iv) and (vii) to step (i).
  • the reheated refrigerants from steps (iv) and (vii) may be combined prior to being returned to step (i).
  • the second portion of the cooled compressed refrigerant is work-expanded in step (vi) in a second turbo-expander.
  • the second turbo- expander may be used to drive a compressor to provide a portion of the compression in step (i).
  • the second turbo-expander may be used to drive a compressor to provide additional compression of the natural gas feed stream in step (c).
  • one or more further portions of the cooled refrigerant may be work-expanded in one or more further turbo-expanders.
  • the one or more further turbo expanders may be used to drive one or more compressors to provide a portion of the compression in step (i), and/or to provide additional compression of the natural gas stream in step (c).
  • the first portion and/or the second portion of the cooled compressed refrigerant from step (ii) may be further cooled by heat exchange in the liquefaction heat exchange system prior to expansion.
  • the first refrigeration cycle comprises both a first turbo-expander and a second turbo-expander
  • the first portion of the cooled compressed refrigerant is fed to the first turbo-expander at a higher temperature than the second portion of the cooled compressed refrigerant fed to the second turbo-expander.
  • the first portion of the cooled compressed refrigerant is fed to the first turbo-expander at a lower temperature than the second portion of the cooled compressed refrigerant fed to the second turbo-expander.
  • the temperature of the respective portions of the cooled compressed refrigerant may be controlled by heat exchange in the liquefaction heat exchange system, as described above.
  • the first refrigeration cycle is a gas refrigeration cycle.
  • the fluid refrigerant is a gas which is successively compressed, cooled, expanded and reheated without changing phase.
  • the gaseous fluid refrigerant comprises or consists of nitrogen gas.
  • gases which do not undergo a phase transition in the refrigeration cycle may also be used, for example air, helium or neon.
  • Gas refrigeration cycles are advantageous when used in offshore applications, and particularly when used in floating applications, as the avoidance of liquid refrigerants through use of an inert gaseous refrigerant translates into reduced space and weight, insensitivity to floating vessel motion, and improved safety.
  • the liquefied natural gas product obtained from the liquefaction heat exchange system is at a higher pressure than the storage systems commonly used in the art, which are usually at or slightly above atmospheric pressure, and usually no more than 125 kPa (absolute).
  • the process of the present invention desirably comprises the step of:
  • the cooled and at least partly condensed natural gas product withdrawn from the liquefaction heat exchange system is expanded to storage pressure using a liquid expander.
  • the liquid expander will typically be coupled to an electrical generator but may be used to drive a compressor to further compress the fluid refrigerant in step (i) or to further compress the natural gas feed stream in step (c).
  • the cooled and at least partly condensed natural gas product withdrawn from the liquefaction heat exchange system may be expanded to storage pressure under adiabatic conditions using a Joule-Thomson valve.
  • the natural gas product will usually comprise a mixture of liquid and vapour, which may be separated in a vapour-liquid separator to provide a LNG product for storage and a vapour stream known as "flash gas".
  • flash gas may optionally be recompressed and combined with the natural gas feed stream and returned to the liquefaction process.
  • the liquefaction heat exchange system used in the process of the present invention may function by passing the expanded cooled refrigerant from step (iii) in direct heat exchange with the compressed natural gas stream in step (d). In other embodiments of the invention, the liquefaction heat exchange system used in the process of the present invention may function by passing the expanded cooled refrigerant from step (iii) in indirect heat exchange with the compressed natural gas stream in step (d), via an intermediate heat exchange fluid or via an intermediate refrigeration cycle.
  • one or more additional refrigeration cycles may be used to supplement the refrigeration provided by the first refrigeration cycle.
  • the one or more additional refrigeration cycles may run in parallel and/or in series with the first refrigeration cycle and may be of any type, including gas and vapour-compression refrigeration cycles.
  • gas and vapour-compression refrigeration cycles In a vapour-compression refrigeration cycle, the refrigerant changes phase between vapour and liquid at the various stages of the refrigeration cycle.
  • Suitable refrigerants for vapour-compression refrigeration cycles include light hydrocarbons, such as methane, ethane, propane and butanes or mixtures thereof.
  • a portion of the natural gas feed may be diverted to act as the refrigerant in a vapour-compression refrigeration cycle.
  • one or more additional refrigeration cycles may be of the type described above, in which a turbo-expander is used to drive a compressor to compress the natural gas feed stream.
  • the cooling fluid in step (ii) may be a fluid refrigerant from an additional refrigeration cycle.
  • the expanded cooled refrigerant from step (iii) may be used as a cooling fluid for an intermediate refrigeration cycle.
  • Cascades of refrigeration cycles are known in the art and, in accordance with the invention, the first refrigeration cycle may occupy any stage of a cascade comprising two or more refrigeration cycles.
  • the expanded cooled refrigerant from step (iii) and the one or more additional refrigerants may each be passed in direct or indirect heat exchange with the compressed natural gas feed stream (step (d)) in the liquefaction heat exchange system.
  • one or more additional refrigerants may be used to pre-cool the compressed natural gas stream in step (d) prior to heat exchange contact with the expanded cooled refrigerant from step (iii).
  • the one or more additional refrigerants may be used to sub-cool the cooled and at least partially condensed natural gas from step (d) following heat exchange contact with the expanded cooled refrigerant from step (iii).
  • the one or more additional refrigerants and the expanded cooled refrigerant from step (iii) may simultaneously be used to cooled and at least partially condense the compressed natural gas stream in step (d), for example where a multi-stream heat exchanger is used in the liquefaction heat exchange system.
  • the expanded cooled refrigerant from step (iii) and the one or more additional refrigerants may also each be used as cooling fluids for an intermediate refrigeration cycle.
  • the compressed natural gas stream is cooled and at least partially condensed in step (d) entirely by heat exchange with the expanded cooled refrigerant from step (iii).
  • the process of the invention does not involve the use of an additional refrigeration cycle. Where only the first refrigeration cycle is used, space and weight requirements are reduced. As noted above, this is advantageous in offshore processes.
  • the heat exchangers used in the liquefaction heat exchange system may be of any type known in the art of natural gas liquefaction.
  • shell and tube heat exchangers for example, shell and tube heat exchangers, plate heat exchangers, plate-fin heat exchangers, spiral wound heat exchangers and diffusion bonded heat exchangers may all be used in the process of the invention.
  • the liquefaction heat exchange system may comprise more than one heat exchanger, for example when an additional refrigeration cycle is run in parallel with the first refrigeration cycle. Multi-stream heat exchangers may also be used.
  • the natural gas feed stream in step (b) preferably has a pressure in the range of from 2000 to 5000 kPa (absolute).
  • the compressed natural gas feed stream from step (c) preferably has a pressure in the range of from 4000 to 10000 kPa (absolute).
  • the natural gas feed stream in step (b) is obtained from an upstream process for the removal of heavy hydrocarbons and/or LPG components and/or water and/or mercury and/or acid gas components.
  • the compressed natural gas stream from step (c) is passed to a process for the removal of heavy hydrocarbons and/or LPG components and/or water and/or mercury and/or acid gas components prior to being passed to the liquefaction heat exchange system in step (d).
  • this invention provides an apparatus for liquefaction of natural gas comprising:
  • step (i) means for cooling the compressed refrigerant from step (i) in heat exchange with a cooling fluid to provide a cooled compressed refrigerant;
  • a first turbo-expander adapted to work-expand at least a first portion of the cooled compressed refrigerant from step (ii) in to provide an expanded cooled refrigerant;
  • step (iv) means for reheating the expanded cooled refrigerant from step (iii) in the liquefaction heat exchange system to provide a reheated refrigerant
  • step (v) means for conveying the reheated refrigerant from step (iv) to step
  • a natural gas feed compressor for compressing a natural gas feed stream
  • step (e) means for withdrawing a cooled and at least partly condensed natural gas product from the liquefaction heat exchange system; wherein the first turbo-expander is adapted to drive the natural gas feed compressor to compress the natural gas feed stream in step (c).
  • the apparatus of the invention is adapted to fully condense and sub-cool the compressed natural gas stream in step (d).
  • the first refrigeration system further comprises:
  • step (vi) means for expanding a second portion of the cooled compressed refrigerant from step (ii);
  • step (vii) means for conveying the expanded cooled refrigerant from step (vi) to the liquefaction heat exchange system to provide a reheated refrigerant;
  • the first refrigeration system may further comprise means for combining the reheated refrigerant from step (iv) with the reheated refrigerant from step (vii) prior to step (viii).
  • the means for expanding a second portion of the cooled compressed refrigerant from step (ii) may comprise a second turbo-expander.
  • the second turbo-expander may advantageously be adapted to drive a second refrigerant compressor in step (i).
  • the second turbo-expander may be adapted to drive a compressor to provide supplementary compression of the natural gas feed stream in step (c).
  • the apparatus of the present invention may comprise one or more further turbo expanders adapted to work-expand one or more further portions of the cooled refrigerant.
  • the one or more further turbo-expanders may be adapted to drive one or more compressors to provide a portion of the compression in step (i), or to provide additional compression of the natural gas stream in step (c).
  • the apparatus of the invention may also comprise means for conveying the first portion and/or the second portion of the cooled compressed refrigerant from step (ii) to the liquefaction heat exchange system for further cooling prior to expansion.
  • the apparatus of the invention preferably comprises means for expanding the cooled and at least partly condensed natural gas product from the liquefaction heat exchange system to storage pressure.
  • the means for expanding the cooled and at least partly condensed natural gas product from the liquefaction heat exchange system to storage pressure comprises a Joule-Thomson valve or a liquid expander.
  • the liquid expander may be adapted to drive a compressor to provide further compression of the natural gas feed stream or to supplement the compression of the fluid refrigerant in step (i).
  • the apparatus of the present invention may further comprise one or more additional refrigeration systems, running in parallel or in series with the first refrigeration system, and which are adapted to supplement the refrigeration provided by the first refrigeration system.
  • the apparatus comprises means for removing heavy hydrocarbons and/or LPG components and/or water and/or mercury and/or acid gas components from the natural gas feed stream prior to liquefaction, which may be disposed upstream or downstream from the natural gas feed compressor.
  • the present invention provides a ship comprising an apparatus as defined above.
  • the present invention provides an offshore platform comprising an apparatus as defined above.
  • the offshore platform may be, for example, a fixed platform, a compliant tower platform, a semi-submersible platform, a jack-up platform, a tension-leg platform, a spar platform or a conductor- support platform.
  • Figure 1 shows a conventional double turbo-expander refrigeration cycle
  • Figure 2 shows a single turbo-expander apparatus for the liquefaction of natural gas in accordance with the present invention
  • Figure 3 shows a double turbo-expander apparatus for the liquefaction of natural gas in accordance with the present invention
  • Figure 4 shows the double turbo-expander apparatus of Figure 3 in conjuction with an upstream pre-treatment process for removal of heavy hydrocarbons, carbon dioxide and water
  • Figure 5 shows the double turbo-expander apparatus of Figure 3 in conjunction with another embodiment of an upstream pre-treatment process for removal of heavy hydrocarbons, carbon dioxide and water.
  • liquefaction feed gas 400 is compressed in cold expander brake compressor 405, driven by the nitrogen refrigeration cycle cold turbo-expander 530.
  • Compressed feed 410 is cooled to ambient conditions in a heat exchanger 415 (typically against air or water) and the cooled compressed gas stream 420 is fed to a multi-stream liquefaction heat exchanger 505 where it is de- superheated, condensed and sub-cooled against nitrogen refrigerant, exiting the heat exchanger 505 as a sub-cooled liquid 425.
  • Liquid product 425 is let down to storage pressure across valve 430 to give two-phase stream 435, which passes to vapour-liquid separator 440 separating an flash gas stream 445 and low pressure LNG product stream 450 for storage.
  • Refrigeration to produce the LNG product stream is provided by a nitrogen refrigeration cycle.
  • Nitrogen is compressed in a two-stage cycle compressor 580/590, incorporating inter and after-coolers 585/595 (typically against air or water) to produce a high-pressure nitrogen stream 500.
  • High-pressure nitrogen stream 500 is cooled in the liquefaction heat exchanger 505 by heat exchange with returning cold low-pressure nitrogen cycle gas 535.
  • Cooled nitrogen cycle gas 525 is work-expanded in a turbo-expander 530 to give a cold low-pressure nitrogen cycle gas 535, which is reheated in the liquefaction heat exchanger 505, cooling the high pressure nitrogen stream 500 and cooling, condensing and sub-cooling the natural gas stream 420.
  • the re-warmed low-pressure nitrogen cycle gas stream 550 is fed to the cycle compressors 580/590 for compression.
  • liquefaction feed gas 400 is compressed in cold cycle brake compressor 405, driven by the cold cycle turbo- expander 530.
  • Compressed feed 410 is cooled to ambient conditions in a heat exchanger 415 (typically against air or water) and the cooled compressed gas stream 420 is fed to a multi-stream liquefaction heat exchanger 505 where it is de-superheated, condensed and sub-cooled against multiple nitrogen refrigerant streams, exiting the exchanger as a sub-cooled liquid 425.
  • Liquid product 425 is let down to storage pressure across valve 430 to give two-phase stream 435, which passes to vapour-liquid separator 440 separating an LNG flash gas stream 445 and low pressure LNG product stream 450 for storage.
  • Refrigeration to produce the LNG product stream is provided by a dual nitrogen refrigeration cycle.
  • Nitrogen is compressed in a two-stage cycle compressor 580/590, incorporating inter- and after-coolers 585/595 (typically against air or water) to produce a high-pressure nitrogen stream 500.
  • High-pressure nitrogen stream 500 is split between warm and cold turbo-expander cycles.
  • Warm nitrogen cycle gas is cooled in the liquefaction heat exchanger 505 to produce a cooled nitrogen gas stream 510 at an intermediate temperature by heat exchange with returning cold low-pressure nitrogen cycle gas 520/535.
  • the resulting cooled nitrogen cycle gas 510 is work-expanded in a warm cycle turbo-expander 515 to give a cold low-pressure nitrogen cycle gas 520 and to drive the warm cycle brake compressor 545.
  • Cold low pressure nitrogen cycle gas 520 is reheated in liquefaction heat exchanger 505, cooling the warm and cold nitrogen cycle feed gas streams and cooling, condensing and sub-cooling the natural gas stream 420.
  • Cold nitrogen cycle gas is cooled in the liquefaction heat exchanger 505 to produce a cooled nitrogen cycle gas stream 525 at a temperature approaching that of the warm cycle turbo-expander discharge stream 520 by heat exchange with returning cold low- pressure nitrogen cycle gas 520/535.
  • Cooled nitrogen cycle gas 525 is work-expanded in a cold cycle turbo-expander 530 to form a cold low-pressure nitrogen stream 535 and to drive cold cycle brake compressor 405.
  • Cold low-pressure nitrogen cycle gas 535 has a pressure similar to that of the warm expander discharge stream 520 and is reheated in th e liquefaction heat exchanger 505, cooling the warm and cold nitrogen cycle feed gas streams and cooling, condensing and sub-cooling the natural gas stream 420.
  • the reheated warm and cold cycle low-pressure nitrogen gas streams 540 are fed to the warm cycle turbo-expander brake compressor 545, driven by the warm cycle turbo- expander 515.
  • the nitrogen cycle gas, boosted in pressure 550, is cooled in a heat exchanger 575 (typically against air or water) and fed to the cycle compressors 580/595for compression.
  • the liquefaction apparatus shown in Figure 3 is integrated with a heavy hydrocarbon removal process based on Joule Thomson expansion of feed gas.
  • Wet natural gas 100 enters the process at elevated pressure.
  • the natural gas feed stream 100, together with liquid stream 395 removed in downstream heavy hydrocarbon removal facilities is fed to an Inlet Separation and Condensate Stabilisation system 105.
  • a liquid stream exits the system as stabilised condensate 110.
  • a vapour stream 200 with reduced heavy hydrocarbon content is fed to the pre-treatment system 210 for removal of acid gas (carbon dioxide) 205 and water 215.
  • Treated gas 300 is cooled to an intermediate temperature and partially condensed by heat exchange with cold residue gas 360 and liquid hydrocarbon 390 in multi-stream heat exchanger 305.
  • the two-phase stream 310 is let down in pressure across valve 315 and fed to a vapour-liquid separator 325.
  • Liquid stream 330 is let down in pressure across valve 370 and combined with liquid stream 380 from the second cold separator 355.
  • Vapour stream 335 at an intermediate pressure is further cooled and condensed in heat exchanger 305.
  • the two-phase stream 340 is let down in pressure across valve 345 and fed to a second vapour-liquid separator 355.
  • Liquid stream 365 is let down in pressure across valve 375 and combined with the liquid stream 385 from the first separator.
  • Combined liquid stream 390 is partially vaporised in heat exchanger 305, providing refrigeration to cool the high pressure gas stream 300 and passed to the upstream Inlet Separator and Condensate Stabilisation system 105.
  • Vapour product 360 with low heavy hydrocarbon content is reheated by heat exchange with high-pressure feed gas 300.
  • the warmed vapour stream 400 is fed to the liquefaction plant.
  • the liquefaction apparatus shown in Figure 3 is integrated with a heavy hydrocarbon removal process based on work-expansion of feed gas.
  • Wet natural gas 100 enters the process at elevated pressure.
  • the natural gas feed stream 100, together with liquid stream 380 removed in downstream heavy hydrocarbon removal facilities is fed to an Inlet Separation and Condensate Stabilisation system 105.
  • a liquid stream exits the system as stabilised condensate 110.
  • a vapour stream 200 with reduced heavy hydrocarbon content is fed to the pre-treatment system 210 for removal of acid gas (carbon dioxide) 205 and water 215.
  • the treated gas stream 300 is cooled and partially condensed by heat exchange with cold residue gas 345 and liquid hydrocarbon 375 in a multi-stream heat exchanger 305.
  • the two-phase stream 310 is fed to a vapour-liquid separator 315.
  • Liquid stream 325 is let down in pressure across valve 365 and combined with the liquid stream 360 from a second cold separator 340.
  • Vapour stream 320 is work-expanded in turbo-expander 330.
  • the resulting two-phase stream 335 is fed to a second vapour-liquid separator 340.
  • Liquid stream 350 is let down in pressure across valve 355 and combined with the liquid stream 370 from the first separator 315.
  • Combined liquid stream 375 is partially vaporised in heat exchanger 305, providing refrigeration to cool the high pressure gas stream 300 and passed to the upstream Inlet Separator and Condensate Stabilisation system 105.
  • Vapour product 345 with low heavy hydrocarbon content is reheated by heat exchange with high-pressure feed gas 300.
  • Warmed vapour stream 385 is compressed in the turbo-expander brake compressor 390, driven by the turbo-expander 330.
  • Treated natural gas, boosted in pressure 395, is cooled in heat exchanger 399 (typically against air or water) and fed to the liquefaction plant as stream 400.
  • the liquefaction system and refrigeration cycle configuration are as described for Figure 3.
  • Predicted performance data is provided for two Examples of this invention. Both Examples demonstrate the recovery of power from work expansion of the refrigeration cycle gas to boost the pressure of the feed gas to liquefaction.
  • the LNG product is sub-cooled such that 5 mol% is flashed on let down to storage pressure across a valve to provide at least part of the plant fuel gas demand.
  • a liquid expander which would generate power, reduce flash vapour generation and reduce refrigeration requirements for sub-cooling.
  • Example 1 This Example corresponds to the embodiment of the invention shown in Figure 4, in which a Joule Thomson process is included for upstream removal of heavy hydrocarbons. This involves cooling and letting down the pre-treated natural gas across a valve to a pressure sufficient to condense the heavy hydrocarbons for removal in a vapour-liquid separator. The number of separation stages required to achieve the required heavy hydrocarbon removal is dependent on the natural gas feed conditions and composition, in this example two separation stages are required.
  • the Joule Thomson process of for heavy hydrocarbon removal is relatively simple, and is able to handle a wide range of flows with high reliability, low space requirements and low weight.
  • Table 1 The composition and conditions of the various streams (as shown in Figure 4) is given in Table 1. Table 1
  • Refrigeration Cycle Compressor Shaft Power (580/590): 74.8 MW 85% Warm Expander-Brake Shaft Power (515) 29.6 MW 82% Cold Expander-Brake Shaft Power (530) 7.1 MW 82%
  • This Example corresponds to the embodiment of the invention shown in Figure 5, in which a turbo-expander process is included for upstream removal of heavy hydrocarbons.
  • the expansion work generated is used to boost the feed to liquefaction.
  • the number of separation stages required to achieve the required heavy hydrocarbon removal is dependent on the natural gas feed conditions and composition, in this example two separation stages are required.
  • the turbo-expander process for heavy hydrocarbon removal of Example 2 has the benefit of recovering power from work expansion of the inlet gas. This is used to drive a feed gas compressor, enabling even higher feed pressure to liquefaction and reduced specific power.
  • Refrigeration Cycle Compressor Shaft Power (580/590): 4.8 MW 85% Warm Expander-Brake Shaft Power (515) 29.6 MW 82% Cold Expander-Brake Shaft Power (530) 7.1 MW 82%
  • Compressor inter-stage/after cooler process streams cooled to 40°C.

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Abstract

La présente invention concerne des procédés et des appareils de liquéfaction de gaz naturel. La présente invention concerne notamment des procédés et des appareils dans lesquels l'expansion d'un réfrigérant dans un turbodétendeur comme une partie d'un cycle de réfrigération est utilisée pour entraîner un compresseur qui fait augmenter la pression de la charge de gaz naturel dans le procédé de liquéfaction. De manière plus spécifique, la présente invention concerne un procédé de liquéfaction de gaz naturel qui comprend les étapes consistant à : (a) fournir un cycle de réfrigération comprenant les étapes consistant à : (i) comprimer un fluide réfrigérant; (ii) refroidir le réfrigérant comprimé de l'étape (i) dans un échange thermique avec un fluide réfrigérant pour fournir un réfrigérant comprimé refroidi; (iii) détendre au moins une première partie du réfrigérant comprimé refroidi de l'étape (ii) dans un premier turbodétendeur pour fournir un réfrigérant refroidi détendu; (iv) réchauffer le réfrigérant refroidi détendu de l'étape (iii) dans un système d'échange thermique de liquéfaction pour fournir un réfrigérant réchauffé; et (v) renvoyer le réfrigérant réchauffé de l'étape (iv) à l'étape (i); (b) fournir un courant de charge de gaz naturel; (c) comprimer le courant de charge de gaz naturel; (d) faire passer le courant de charge de gaz naturel comprimé directement ou indirectement dans l'échangeur thermique avec le réfrigérant refroidi dilaté de l'étape (iii) dans le système échangeur thermique de liquéfaction; et (e) soutirer un gaz naturel refroidi et au moins partiellement condensé du système échangeur thermique de liquéfaction; le premier turbodétendeur étant utilisé pour entraîner un compresseur à comprimer le courant de charge de gaz naturel dans l'étape (c).
PCT/GB2011/050779 2010-04-30 2011-04-19 Procédé et appareil de liquéfaction de gaz naturel WO2011135335A2 (fr)

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WO2016003628A1 (fr) * 2014-07-03 2016-01-07 Uop Llc Procédés et appareils pour la liquéfaction de flux d'hydrocarbures
US10267559B2 (en) 2015-04-10 2019-04-23 Chart Energy & Chemicals, Inc. Mixed refrigerant liquefaction system and method
US10619918B2 (en) 2015-04-10 2020-04-14 Chart Energy & Chemicals, Inc. System and method for removing freezing components from a feed gas
US10072889B2 (en) 2015-06-24 2018-09-11 General Electric Company Liquefaction system using a turboexpander
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CN113710978A (zh) * 2019-04-01 2021-11-26 林德有限责任公司 用于液化气体的方法和设备
CN110345376A (zh) * 2019-06-28 2019-10-18 四川泰博流体科技有限公司 一种纯化气液化的方法、储存的方法及液化的装置
CN110260148A (zh) * 2019-06-28 2019-09-20 四川泰博流体科技有限公司 一种液态空气的储存设备、方法及空气液化装置

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EP2564139B1 (fr) 2020-06-17
EP2564139A2 (fr) 2013-03-06
AU2011247081A1 (en) 2012-12-13
GB2479940B (en) 2012-09-05

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