WO2022005270A1 - Fractionnement de déséthaniseur divisé - Google Patents

Fractionnement de déséthaniseur divisé Download PDF

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Publication number
WO2022005270A1
WO2022005270A1 PCT/MY2020/050048 MY2020050048W WO2022005270A1 WO 2022005270 A1 WO2022005270 A1 WO 2022005270A1 MY 2020050048 W MY2020050048 W MY 2020050048W WO 2022005270 A1 WO2022005270 A1 WO 2022005270A1
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Prior art keywords
stage
gas
liquid
upper section
lower section
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PCT/MY2020/050048
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English (en)
Inventor
Ian Johnson
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Drl Engineering Sdn Bhd
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Priority to PCT/MY2020/050048 priority Critical patent/WO2022005270A1/fr
Publication of WO2022005270A1 publication Critical patent/WO2022005270A1/fr

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    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G5/00—Recovery of liquid hydrocarbon mixtures from gases, e.g. natural gas
    • C10G5/06—Recovery of liquid hydrocarbon mixtures from gases, e.g. natural gas by cooling or compressing
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G33/00—Dewatering or demulsification of hydrocarbon oils
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G33/00—Dewatering or demulsification of hydrocarbon oils
    • C10G33/08—Controlling or regulating
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
    • C10L3/00—Gaseous fuels; Natural gas; Synthetic natural gas obtained by processes not covered by subclass C10G, C10K; Liquefied petroleum gas
    • C10L3/06—Natural gas; Synthetic natural gas obtained by processes not covered by C10G, C10K3/02 or C10K3/04
    • C10L3/10—Working-up natural gas or synthetic natural gas
    • C10L3/101—Removal of contaminants
    • C10L3/106—Removal of contaminants of water
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
    • C10L3/00—Gaseous fuels; Natural gas; Synthetic natural gas obtained by processes not covered by subclass C10G, C10K; Liquefied petroleum gas
    • C10L3/06—Natural gas; Synthetic natural gas obtained by processes not covered by C10G, C10K3/02 or C10K3/04
    • C10L3/10—Working-up natural gas or synthetic natural gas
    • C10L3/107—Limiting or prohibiting hydrate formation
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J3/00—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification
    • F25J3/02—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream
    • F25J3/0204—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream characterised by the feed stream
    • F25J3/0209—Natural gas or substitute natural gas
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J3/00—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification
    • F25J3/02—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream
    • F25J3/0228—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream characterised by the separated product stream
    • F25J3/0233—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream characterised by the separated product stream separation of CnHm with 1 carbon atom or more
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J3/00—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification
    • F25J3/02—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream
    • F25J3/0228—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream characterised by the separated product stream
    • F25J3/0242—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream characterised by the separated product stream separation of CnHm with 3 carbon atoms or more
    • 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
    • F25J2200/00—Processes or apparatus using separation by rectification
    • F25J2200/04—Processes or apparatus using separation by rectification in a dual pressure main column system
    • 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
    • F25J2200/00—Processes or apparatus using separation by rectification
    • F25J2200/30—Processes or apparatus using separation by rectification using a side column in a single pressure column system
    • 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
    • F25J2200/00—Processes or apparatus using separation by rectification
    • F25J2200/70—Refluxing the column with a condensed part of the feed stream, i.e. fractionator top is stripped or self-rectified
    • 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
    • F25J2205/00—Processes or apparatus using other separation and/or other processing means
    • F25J2205/02—Processes or apparatus using other separation and/or other processing means using simple phase separation in a vessel or drum
    • F25J2205/04—Processes or apparatus using other separation and/or other processing means using simple phase separation in a vessel or drum in the feed line, i.e. upstream of the fractionation step
    • 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
    • F25J2205/00—Processes or apparatus using other separation and/or other processing means
    • F25J2205/60—Processes or apparatus using other separation and/or other processing means using adsorption on solid adsorbents, e.g. by temperature-swing adsorption [TSA] at the hot or cold end
    • 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
    • F25J2215/00—Processes characterised by the type or other details of the product stream
    • F25J2215/60—Methane
    • 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
    • F25J2220/00—Processes or apparatus involving steps for the removal of impurities
    • F25J2220/60—Separating impurities from natural gas, e.g. mercury, cyclic hydrocarbons
    • F25J2220/68—Separating water or hydrates
    • 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
    • F25J2240/00—Processes or apparatus involving steps for expanding of process streams
    • F25J2240/02—Expansion of a process fluid in a work-extracting turbine (i.e. isentropic expansion), e.g. of the feed stream
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J2290/00—Other details not covered by groups F25J2200/00 - F25J2280/00
    • F25J2290/40—Vertical layout or arrangement of cold equipments within in the cold box, e.g. columns, condensers, heat exchangers etc.

Definitions

  • the present invention relates to the field of natural gas and condensate processing for the extraction of natural gas liquids.
  • Hydrocarbon production streams in the upstream and midstream sectors of the industry frequently comprise a mixture of natural gas, natural gas liquids, condensate and a proportion of non-hydrocarbon components including water. It is typically required to separate such hydrocarbon streams according to boiling point into products and remove impurities such as water for downstream processes and consumers.
  • hydrocarbon gas frequently results in a mixed phase fluid stream at surface production facilities, comprising hydrocarbon gas, hydrocarbon liquid and free water.
  • the first processing step at the surface facilities is gravity separation of the produced well fluid to produce separate gas, liquid hydrocarbon and produced water streams.
  • the water stream is disposed of after further treatment to reduce the level of hydrocarbons and other contaminants in the water to within disposal limits.
  • the gas and liquid hydrocarbon streams both require further processing before they can meet specifications for transport, storage and sale to downstream users.
  • the gas stream is saturated with both water vapour and heavier hydrocarbons at separation conditions, and partial condensation of both phases will occur in the event of temperature reduction or pressure change. Both the water and hydrocarbon dewpoint must be reduced in order to bring the gas to sales quality.
  • the liquid stream comprises mixed hydrocarbons of varying molecular weights. Any pressure reduction will result in vaporisation of the lighter hydrocarbon species. This presents problems in the handling and storage of the liquid.
  • both the gas and liquid streams contain significant quantities of propane and butane, which have a higher value as separate products, compared to leaving them in the sales gas and stabilised condensate. Recovery of these valuable components from gas is important in the industry using well established processes.
  • the invention integrates the gas and liquid treatment processes into a single process that is tolerant to the presence of water in some of the feedstreams, whilst also using cryogenic fractionation to achieve high NGL recovery.
  • One embodiment of the invention is a system for processing gas, liquid or mixed phase hydrocarbon feed streams, using a single fractionation column that comprises; an upper section that operates below hydrate formation and water freezing temperatures, receiving feed streams that have been dehydrated, typically to ppm or lower levels; a lower section that operates at elevated temperatures and receives gas, liquid or mixed phase hydrocarbon feed streams that may contain water and/or water vapour; a reboiler unit for re-boiling the liquid from the bottom of the lower section and returns gas to the lower section; an inter-stage dehydration unit for dehydrating the gas stream from the top stage of the lower section and feeding the dehydrated gas to the bottom stage of the upper section; an inter-stage pump for pumping the liquid from the bottom stage of the upper section to the top stage of the lower section; the entire system forming a single fractionation unit, characterized in that the fractionation unit has a warm section that is tolerant to the presence of water, a single mid-section, an inter-stage dehydration unit, wherein the vapour from the
  • the hydrocarbon gas and liquid fractions are processed in a single fractionation unit, in which a dehydration unit is positioned between adjacent intermediate stages of the fractionation unit, such that the system efficiently process and allows low temperature fractionation stages leading to a high Natural Gas Liquids (NGL) recovery.
  • NNL Natural Gas Liquids
  • the upper section and the lower section are incorporated in a single vessel, such that the bottom stage of the upper section and the top stage of the lower section constitute two adjacent stages of the fractionator, therefore gas evolved from the top stage of the lower section is channelled to the bottom stage of the upper section, whilst liquid from the bottom stage of the upper section channelled to the top stage of the lower section.
  • the inter-stage pump is used for overcoming pressure difference between the lower section and the upper section resulting from the inter-stage dehydration unit.
  • the gas from the top stage of the lower section is channelled to the bottom stage of the upper section, whilst liquid from the bottom stage of the upper section channelled to the top stage of the lower section.
  • the upper section operates with a minimum temperature that is below the water freezing and/or hydrate formation temperature.
  • the hydrocarbon gas which contain water vapour is dehydrated by molecular sieve dehydration.
  • the dehydrated hydrocarbon gas is cooled, partially condensed, separated and processed for purposes of improving product recovery or improving thermodynamic efficiency.
  • At least one gas evolved from the top stage of the lower section passes through the dehydration unit to remove water vapour before being channelled to the bottom of the upper section.
  • the dehydration unit introduces a pressure drop to the gas stream, such that the lower section operates at one to two bar higher pressure than the upper section and the liquid from the bottom stage of the upper section is pumped to the top stage of the lower section.
  • An alternative embodiment of the invention is a system for processing gas, liquid or mixed phase hydrocarbon feed streams, using a single fractionation unit in two separate vessels that comprises; an upper column that operates below hydrate formation and/or water freezing temperatures, receiving feed streams that have been dehydrated, typically to ppm or lower levels; a lower column that operates at elevated temperatures and receives gas, liquid or mixed phase hydrocarbon feed streams that may contain water and/or water vapour; a reboiler unit for re-boiling the liquid from the bottom of the lower column and returns gas to the lower column; an inter-stage dehydration unit for dehydrating the gas stream from top stage of the lower column and feeding the dehydrated gas to the bottom stage of the upper column; an inter stage pump for pumping the liquid from the bottom stage of the upper column to the top
  • the upper section and the lower section are incorporated in two separate vessels, such that the bottom stage of the upper section and the top stage of the lower section constitute two adjacent stages of the fractionator, therefore gas evolved from the top stage of the lower section is channelled to the bottom stage of the upper section, whilst liquid from the bottom stage of the upper section channelled to the top stage of the lower section.
  • Another embodiment of invention is a method of processing gas and liquid fractionation, comprising steps of; setting a upper section having the gas, liquid or mixed phase hydrocarbon feed streams dehydrated typically to ppm or lower levels, to operate below hydrate formation and/or water freezing temperatures; setting a lower section having the gas, liquid or mixed phase hydrocarbon feed streams with a water or water vapour content to an elevated temperatures; re-boiling the gas, liquid or mixed phase hydrocarbon feed streams using a reboiler unit; dehydrating the re-boiled gas, liquid or mixed phase hydrocarbon feed streams coming from top stage of the lower section and feeding to bottom stage of the upper section, using an inter-stage dehydration unit; pumping at least one liquid formed at the bottom stage of the upper section to the top stage of the lower section using an inter-stage pump; and performing fractionation process using a fractionation unit, characterized in that the fractionation unit having a warm section for fractionation in the presence of water, channelling a plurality of dehydrated vapour traffic from the warm section to the upper fractionation section
  • the hydrocarbon gas and liquid fractions processed in a single fractionation unit in which the dehydration unit positioned in the mid-section of the fractionation unit, such that all of the gas exiting the fractionation unit has passed through the lowest temperature section of the unit, such that the system efficiently processes and allows low temperature fractionation leading to a high Natural Gas Liquids (NGL) recovery.
  • NNL Natural Gas Liquids
  • the upper section and the lower section are incorporated in a single vessel to constitute two adjacent stages of the fractionator unit, such that a gas evolved from the top stage of the lower section channelled to the bottom stage of the upper section, whilst a liquid from the bottom stage of the upper section channelled to the top stage of the lower section.
  • Figure 1 illustrates a processing system for gas, liquid or mixed phase hydrocarbon feed streams or Split Deethaniser, having an inter-stage dehydration.
  • Figure 2 illustrates an overall process scheme from well fluids reception through to Natural Gas Liquids (NGL) production that utilises a split deethaniser.
  • NNL Natural Gas Liquids
  • the general principles of the present invention address the issue of loss of thermodynamic efficiency associated with the traditional approach of separate, independent processing of the gas and liquid fractions of a mixed phase gas- condensate well fluid stream for the extraction of Natural Gas Liquids (NGL).
  • NNL Natural Gas Liquids
  • the hydrocarbon gas and hydrocarbon liquid phases are processed separately for the recovery of NGL’s: i)
  • the hydrocarbon liquid stream (which contains water) is processed by fractional distillation, stabilised to remove predominantly butane and lighter components, leaving a stable condensate product of predominantly pentane and heavier components, which has a vapour pressure of less than atmospheric pressure at prevailing ambient temperatures.
  • the condensate stabiliser operates at minimum temperatures that are higher than water freezing or hydrate formation temperatures, and can thus tolerate the presence of water in the feed stream.
  • the removed NGLs and lighter hydrocarbons are extracted from the stabiliser together with water vapour as a gas which may then be recycled to the gas stream for further processing (see (ii) below).
  • the water saturated hydrocarbon gas stream is processed to recover NGL’s by absorption, cryogenic fractionation, or a combination of the two. Where the selected NGL recovery process operates at sub-zero temperatures, the gas must first be dehydrated, typically to sub ppm levels, to prevent hydrate formation, freezing and blockage within the process equipment.
  • the water saturated overhead gas stream from condensate stabilisation (described in (i) above) may also be fed to the NGL recovery system, and would also require pre-treatment for water removal. This separate processing of the gas and liquid phases and recycle of the overhead gas stream from the liquid treatment process to the gas treatment process results in; a) thermodynamic inefficiency as the liquid stabilisation process must typically input sufficient energy to heat the entire overhead gas stream to the required operating temperature to exit the fractionation column.
  • thermodynamic efficiency could be achieved by processing the hydrocarbon gas and liquid fractions together in a single fractionation step, but the presence of water in the liquid hydrocarbon phase introduces an obstacle to the use of low temperature processes which are essential for high Natural Gas Liquids (NGL) recovery.
  • NNL Natural Gas Liquids
  • the proposed invention allows the hydrocarbon gas and liquid fractions to be processed together in a single fractionation unit, referred to here as the “Split Deethaniser” by the addition of a dehydration stage located in the mid-section of the fractionator. This provides a thermodynamically efficient process and allows low temperature fractionation stages leading to high Natural Gas Liquids (NGL) recovery.
  • NNL Natural Gas Liquids
  • the upper section of the Split Deethaniser operates with a minimum temperature that is below the water freezing and/or hydrate formation temperature.
  • the water saturated hydrocarbon gas phase is dehydrated, typically by molecular sieve dehydration. It is then cooled, partially condensed, separated and possibly undergoes further processing stages for purposes of improving product recovery and/or improving thermodynamic efficiency before being sent to the upper section of the Split Deethaniser.
  • Further processing steps may involve turbo expansion, cooling by mechanical refrigeration and/or heat and mass transfer integration by a variety of proprietary and open art methods and are not the subject of the proposed innovation.
  • Hydrocarbon liquids, containing water, are fed into the top of the Split Deethaniser lower section, together with liquid from the bottom of the Split Deethaniser upper section.
  • the upper and lower sections of the Split Deethaniser may be incorporated in a single vessel, or may be accommodated in separate vessels.
  • the bottom stage of the Split Deethaniser upper section and the top stage of the Split Deethaniser lower section constitute two adjacent stages of the fractionator, therefore gas evolved from the top stage of the lower section flows to the bottom stage of the upper section, whilst liquid from the bottom stage of the upper section flows to the top stage of the lower section.
  • the gas evolved from the top of the lower section passes through a dehydration stage (typically molecular sieve dehydration), to remove water vapour before being passed to the bottom of the upper column.
  • a dehydration stage typically molecular sieve dehydration
  • the entire Split Deethaniser comprises the parts listed below:
  • Deethaniser Upper Section (101) operates at sub-zero temperatures, with water content of feed streams reduced to sufficiently low level to prevent hydrate formation or freezing in the column ;
  • Deethaniser Lower Section (102) operates at elevated temperatures (higher than water freezing and hydrate formation temperature), contains water / water vapour;
  • Deethaniser reboiler (103) - a heat exchanger which heats liquids from the bottom of the lower section of the Deethaniser, partially vapourises the liquids and returns the vapour to the bottom tray of the lower section of the Deethaniser;
  • Deethaniser Interstage dehydration (104) - gas from top of lower section is dehydrated and fed to bottom stage of upper section;
  • Deethaniser Interstage Pump. (105)- Liquid from base of upper section is pumped into top of lower section. Pump is required to overcome pressure difference between lower and upper stages resulting from interstage dehydration;
  • Deethaniser Lower Section Top Feed stream (109) typically water wet, rich, ambient or higher temperature
  • Additional feed streams to Deethaniser Upper Section (110) rich, may be water wet or dry
  • Inlet separator (201) - provides bulk separation of the hydrocarbon gas, hydrocarbon liquid and aqueous phases
  • Condensate coalescer (202) removes distributed water from the hydrocarbon liquids down to the level required for operation of the deethaniser;
  • Feed Gas Dehydration (204) removes water vapour from the feed gas down to levels required for satisfactory operation of the cryogenic Natural Gas Liquids (NGL) removal system (likely to ppm levels or lower);
  • Subcooler (208) - heat exchanger to chill a portion of chilled feed gas against returning deethaniser overhead gas, to produce a liquid wash for the deethaniser;
  • the Split Deethaniser system is best engaged in a scenario where water wet gaseous and liquid hydrocarbon phases are present, recovery of Natural Gas Liquids (NGL) is required and there are no existing process units with available capacities or synergies that would make alternative Natural Gas Liquids (NGL) recovery schemes more economic. This would typically be the case for Natural Gas Liquids (NGL) recovery from well fluids with a high Condensate-Gas Ratio (CGR) in a remote, greenfield location.
  • CGR Condensate-Gas Ratio
  • the proposed invention is applicable to Upstream and Midstream oil and gas production (onshore and offshore).
  • the proposed invention is also applicable but not limited to Gas processing facilities or refineries where multiple, multiphase gas and liquid feed streams are present.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Mechanical Engineering (AREA)
  • Thermal Sciences (AREA)
  • General Engineering & Computer Science (AREA)
  • Separation By Low-Temperature Treatments (AREA)

Abstract

La présente invention concerne un système de traitement de flux d'alimentation en hydrocarbures en phase gazeuse, liquide ou mixte, comprenant : une section de fractionnement à étages multiples supérieure destinée à fonctionner à des températures inférieures à la formation d'hydrates et/ou à la température de congélation de l'eau pour les flux d'alimentation en hydrocarbures en phase gazeuse, liquide ou mixte ne contenant pas d'eau ; une section de fractionnement à étages multiples inférieure fonctionnant à des températures élevées qui sont tolérantes à la présence d'eau pour les flux d'alimentation en hydrocarbures en phase gazeuse, liquide ou mixte contenant de l'eau ou de la vapeur d'eau ; une unité de rebouilleur pour rebouillir le liquide qui s'accumule dans la base de la colonne inférieure ; une unité de déshydratation inter-étage pour déshydrater le gaz provenant de l'étage supérieur de la section inférieure et le fournir à l'étage inférieur de la section supérieure ; une pompe inter-étage pour pomper le liquide qui s'accumule au niveau de l'étage inférieur de la section supérieure vers l'étage supérieur de la section inférieure. L'ensemble comprend une seule unité de fractionnement destinée à effectuer un traitement de fractionnement de telle sorte qu'une teneur en liquides de gaz naturel est séparée des flux d'alimentation d'hydrocarbures en phase gazeuse, liquide, ou mixte par actionnement de l'unité de fractionnement à des températures inférieures à la température de formation d'hydrate et/ou au point de congélation de l'eau.
PCT/MY2020/050048 2020-07-01 2020-07-01 Fractionnement de déséthaniseur divisé WO2022005270A1 (fr)

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Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2584087A1 (fr) * 1985-06-26 1987-01-02 Petrol Engineering Sa Procede pour le traitement des effluents des champs petroliers
US4717408A (en) * 1986-08-01 1988-01-05 Koch Process Systems, Inc. Process for prevention of water build-up in cryogenic distillation column
US5030339A (en) * 1988-10-21 1991-07-09 Costain Engineering Limited Separation of gas and oil mixtures
US6182469B1 (en) * 1998-12-01 2001-02-06 Elcor Corporation Hydrocarbon gas processing
US20040206112A1 (en) * 2002-05-08 2004-10-21 John Mak Configuration and process for ngli recovery using a subcooled absorption reflux process
AU2012261477A1 (en) * 2003-02-07 2013-01-10 Shell Internationale Research Maatschappij B.V. Process for removing contaminants from natural gas
US20150276308A1 (en) * 2012-10-01 2015-10-01 Stamicarbon B.V. Acting Under The Name Of Mt Innovation Center Process for the removal of co2 from acid gas
CN209974700U (zh) * 2019-05-28 2020-01-21 四川华气清源科技有限公司 一种模块化的分子筛脱水橇

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2584087A1 (fr) * 1985-06-26 1987-01-02 Petrol Engineering Sa Procede pour le traitement des effluents des champs petroliers
US4717408A (en) * 1986-08-01 1988-01-05 Koch Process Systems, Inc. Process for prevention of water build-up in cryogenic distillation column
US5030339A (en) * 1988-10-21 1991-07-09 Costain Engineering Limited Separation of gas and oil mixtures
US6182469B1 (en) * 1998-12-01 2001-02-06 Elcor Corporation Hydrocarbon gas processing
US20040206112A1 (en) * 2002-05-08 2004-10-21 John Mak Configuration and process for ngli recovery using a subcooled absorption reflux process
AU2012261477A1 (en) * 2003-02-07 2013-01-10 Shell Internationale Research Maatschappij B.V. Process for removing contaminants from natural gas
US20150276308A1 (en) * 2012-10-01 2015-10-01 Stamicarbon B.V. Acting Under The Name Of Mt Innovation Center Process for the removal of co2 from acid gas
CN209974700U (zh) * 2019-05-28 2020-01-21 四川华气清源科技有限公司 一种模块化的分子筛脱水橇

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