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WO2006108821A1 - Method and apparatus for liquefying a natural gas stream - Google Patents

Method and apparatus for liquefying a natural gas stream Download PDF

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Publication number
WO2006108821A1
WO2006108821A1 PCT/EP2006/061470 EP2006061470W WO2006108821A1 WO 2006108821 A1 WO2006108821 A1 WO 2006108821A1 EP 2006061470 W EP2006061470 W EP 2006061470W WO 2006108821 A1 WO2006108821 A1 WO 2006108821A1
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WO
WIPO (PCT)
Prior art keywords
stream
pressure
bar
vaporous
feed stream
Prior art date
Application number
PCT/EP2006/061470
Other languages
French (fr)
Inventor
Cornelis Buijs
Willem Dam
Emilius Carolus Joanes Nicolaas De Jong
Original Assignee
Shell Internationale Research Maatschappij
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 Shell Internationale Research Maatschappij filed Critical Shell Internationale Research Maatschappij
Priority to US11/918,162 priority Critical patent/US20090064713A1/en
Priority to EP06725670A priority patent/EP1869382A1/en
Publication of WO2006108821A1 publication Critical patent/WO2006108821A1/en

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Classifications

    • 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
    • F25J1/02Processes 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
    • F25J1/0228Coupling of the liquefaction unit to other units or processes, so-called integrated processes
    • F25J1/0235Heat exchange integration
    • F25J1/0237Heat exchange integration integrating refrigeration provided for liquefaction and purification/treatment of the gas to be liquefied, e.g. heavy hydrocarbon removal from natural gas
    • F25J1/0238Purification or treatment step is integrated within one refrigeration cycle only, i.e. the same or single refrigeration cycle provides feed gas cooling (if present) and overhead gas cooling
    • 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
    • F25J1/02Processes 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
    • 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"
    • F25J1/0042Processes 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 liquid 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
    • F25J1/0047Processes 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
    • F25J1/0052Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the kind of cold generation within the liquefaction unit for compensating heat leaks and liquid production using an "external" refrigerant stream in a closed vapor compression cycle by vaporising a liquid refrigerant stream
    • F25J1/0055Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the kind of cold generation within the liquefaction unit for compensating heat leaks and liquid production using an "external" refrigerant stream in a closed vapor compression cycle by vaporising a liquid refrigerant stream originating from an incorporated cascade
    • 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
    • F25J1/02Processes 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
    • F25J1/0211Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process using a multi-component refrigerant [MCR] fluid in a closed vapor compression cycle
    • F25J1/0214Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process using a multi-component refrigerant [MCR] fluid in a closed vapor compression cycle as a dual level refrigeration cascade with at least one MCR cycle
    • 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
    • F25J1/02Processes 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
    • F25J1/0211Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process using a multi-component refrigerant [MCR] fluid in a closed vapor compression cycle
    • F25J1/0214Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process using a multi-component refrigerant [MCR] fluid in a closed vapor compression cycle as a dual level refrigeration cascade with at least one MCR cycle
    • F25J1/0215Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process using a multi-component refrigerant [MCR] fluid in a closed vapor compression cycle as a dual level refrigeration cascade with at least one MCR cycle with one SCR cycle
    • F25J1/0216Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process using a multi-component refrigerant [MCR] fluid in a closed vapor compression cycle as a dual level refrigeration cascade with at least one MCR cycle with one SCR cycle using a C3 pre-cooling cycle
    • 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
    • F25J2205/00Processes or apparatus using other separation and/or other processing means
    • F25J2205/02Processes or apparatus using other separation and/or other processing means using simple phase separation in a vessel or drum
    • 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
    • F25J2220/00Processes or apparatus involving steps for the removal of impurities
    • F25J2220/60Separating impurities from natural gas, e.g. mercury, cyclic hydrocarbons
    • F25J2220/64Separating heavy hydrocarbons, e.g. NGL, LPG, C4+ hydrocarbons or heavy condensates in general
    • 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
    • F25J2230/60Processes or apparatus involving steps for increasing the pressure of gaseous process streams the fluid being hydrocarbons or a mixture of hydrocarbons

Definitions

  • the present invention relates to a method of liquefying a natural gas stream.
  • LNG liquefied natural gas
  • HHC Heavy Hydrocarbon
  • a problem of the method according to DE 102 26 597 is that it is unnecessarily complicated.
  • a further problem of the above method is that it needs a relatively high cooling duty in the heat exchanger (s) for liquefying the natural gas.
  • step (a) providing a feed stream containing natural gas at a pressure of 10-80 bar, preferably 10-50 bar; (b) supplying the feed stream provided in step (a) to a gas/liquid separator;
  • step (d) compressing the vaporous stream obtained in step (c) thereby obtaining a compressed stream having a pressure of at least 70, preferably at least 84 bar; (e) liquefying the compressed stream obtained in step (d) thereby obtaining a liquefied natural gas stream; wherein the compressed stream obtained in step (d) , before it is liquefied in step (e) , is heat exchanged against the vaporous stream obtained in step (c) , and wherein the pressure of the feed stream as provided in step (a) is not increased until the compressing in step (d) .
  • a further advantage of the present invention is that an increased production of liquefied natural gas can be obtained using a given refrigeration power.
  • the method according to the present invention provides more LNG than a known process. It has been found that according to the present invention increases in LNG product as high as 20% may be obtained, while keeping the refrigeration power constant.
  • US 2004/0079107 Al discloses the heat exchanging of a compressed stream against a vaporous stream obtained from a distillation column.
  • US 2004/0079107 Al teaches away from the present invention, as paragraphs [0032] and [0033] (while referring to Figure 4) of US 2004/0079107 Al suggest to perform the liquefaction at lower pressures.
  • the natural gas stream may be any suitable gas stream to be liquefied, but is usually obtained from natural gas or petroleum reservoirs.
  • the natural gas may also be obtained from another source, also including a synthetic source such as a Fischer-Tropsch process.
  • the natural gas stream is comprised substantially of methane.
  • the feed stream comprises at least 60 mol% methane, more preferably at least 80 mol%, most preferably the feed stream comprises at least 90 mol% methane.
  • the natural gas may contain varying amounts of hydrocarbons heavier than methane such - A - as ethane, propane, butanes and pentanes as well as some aromatic hydrocarbons.
  • the natural gas stream may also contain non-hydrocarbons such as H2O, N2, CO2, H2S and other sulphur compounds, and the like.
  • the feed stream containing the natural gas may be pre-treated before feeding it to the gas/liquid separator. This pre-treatment may comprise removal of undesired components such as CO2 and H2S, or other steps such as pre-cooling, pre-pressurizing or the like. As these steps are well known to the person skilled in the art, they are not further discussed here.
  • the gas/liquid separator may be any suitable means for obtaining a vaporous stream and a liquid stream, such as a scrubber, distillation column, etc. If desired, two or more gas/liquid separators may be present.
  • the increase in pressure of the vaporous stream may be performed in various ways, provided that a pressure of at least 70, preferably at least 84 bar is obtained.
  • the pressure in step (d) is increased by compressing the vaporous stream in a compressor, thereby obtaining a compressed stream.
  • one or more compressors may be used.
  • the liquefaction of the pressurized vaporous stream may be performed in various ways, e.g. using one or more cryogenic heat exchangers.
  • the liquefied natural gas may be further processed, if desired.
  • the obtained LNG may be depressurized by means of a Joule-Thomson valve or by means of a cryogenic turbo- expander.
  • further intermediate processing steps between the gas/liquid separation and the liquefaction may be performed.
  • the pressure is increased to at least 86 bar, preferably at least 90 bar.
  • the amount of LNG product obtained may be increased.
  • the vaporous stream may be supercritical, depending on the prevailing pressure and the composition of the respective vaporous stream.
  • the vaporous stream is supercritical, as this avoids phase changes in the liquefaction process.
  • the vaporous stream obtained in step (c) has a C5 "1" content of below 0.5 mol%, preferably below 0.1 mol%. This minimizes operating problems in the downstream liquefaction unit.
  • C5 "1" content is meant the content of hydrocarbon components having five or more carbon atoms.
  • the compressed stream obtained in step (d) is cooled, e.g. in an ambient heat exchanger. Further it is preferred that the compressed stream is heat exchanged against the vaporous stream obtained in step (c) .
  • the feed stream, before supplying to the gas/liquid separator in step (b) is expanded.
  • the feed stream is expanded to a pressure ⁇ (below) 35 bar.
  • an expander for expanding the feed stream is functionally coupled to a compressor for compressing the vaporous stream.
  • the power generated by the expander is used at least partially for driving the compressor to which it is functionally coupled.
  • the expander and compressor form a so-called “compressor-expander scheme", as a result of which the energy consumption of the whole process is minimized.
  • compressor-expander scheme As the person skilled in the art will readily understand what is meant with a “compressor-expander scheme”, this is not further discussed here.
  • the present invention relates to LNG product obtained by the method according to the present invention, in particular liquefied methane.
  • the present invention relates to an apparatus suitable for performing the method according to the present invention, the apparatus at least comprising: - means for providing a feed stream containing natural gas at a pressure of 10-80 bar, preferably 10-50 bar; a gas/liquid separator for separating the feed stream into a vaporous stream and a liquid stream, the vaporous stream being enriched in methane relative to the feed stream, and the liquid stream being reduced in methane relative to the feed stream; a compressor for increasing the pressure of the vaporous stream obtained in the gas/liquid separator to a pressure of at least 70, preferably at least 84 bar, thereby obtaining a compressed stream; a heat exchanger for heat exchanging the compressed stream against the vaporous stream obtained from the gas/liquid separator; and a liquefaction unit for liquefying an effluent from the heat exchanger having a pressure of at least 70, preferably at least 84 bar, the liquefaction unit comprising at least one cryogenic heat exchanger.
  • the apparatus further comprises an expander for expanding the feed stream.
  • the compressor and expander are functionally coupled, thereby forming a so-called "compressor-expander scheme".
  • FIG. 1 schematically a process scheme in accordance with an embodiment of the present invention.
  • Fig. 2 schematically a process scheme in accordance with another embodiment of the present invention.
  • a single reference number will be assigned to a line as well as a stream carried in that line. Same reference numbers refer to similar components.
  • FIG 1 schematically shows a base load liquefied natural gas (LNG) export process and an apparatus
  • a feed stream 10 containing natural gas is supplied to a gas/liquid separator 31 at a certain inlet pressure and inlet temperature.
  • the feed stream 10 is pre-cooled against a refrigerant in a heat exchanger 11.
  • the inlet pressure to heat exchanger 11 will be between 10 and 80 bar (preferably ⁇ (below) 50 bar) , and the temperature will be close to ambient temperature, usually between 5 and 50 0 C.
  • the feed stream 10 may have been pre-treated before it is fed to the separator 31.
  • the feed stream 10 may be expanded (as also shown in the embodiment of Figure 2 hereafter; in expander 12) .
  • the feed stream 10 is pre-cooled against a refrigerant in a heat exchanger 11, or in a train of heat exchangers, for instance comprising two or more heat exchangers operating at different refrigerant pressure levels.
  • the pre-cooled feed stream in line 20 is at a pre-cooling temperature that is lower than the temperature in line 10.
  • the pre-cooling temperature is chosen to form a partially condensed feed stream 20. Further, the pre- cooling temperature is chosen to optimise a subsequent separation step in separator 31.
  • stream 20 is fed to the gas/liquid separator 31.
  • the feed stream in line 20 is separated into a vaporous overhead stream 40 and a liquid bottom stream 30.
  • the overhead stream 40 is enriched in methane (and usually also ethane) relative to the feed stream 20.
  • the bottom stream 30 is generally liquid and usually contains some components that are freezable when they would be brought to a temperature at which methane is liquefied.
  • Separator 31 can be a separator vessel or a distillation column such as a scrub column, depending on the separation required to remove freezable components from the feed stream.
  • the freezable components are CO2, H2S and hydrocarbon components having the molecular weight of pentane or higher. These freezable components may also at least partially have been removed from the feed stream before entering the separator 31.
  • the bottom stream 30 may also contain hydrocarbons that can be separately processed to form liquefied petroleum gas (LPG) products.
  • LPG liquefied petroleum gas
  • the bottom stream 30 is subjected to one or more fractionation steps to collect various natural gas liquid products.
  • the overhead stream 40 is led through an effluent stream heat exchanger 41, where it is indirectly heated against a stream of about ambient temperature (stream 70) .
  • Stream 50 which is discharged from the effluent stream heat exchanger 41 is then compressed via compressor 51 or a train of two or more compressors.
  • the compressed stream is discharged at a pressure above 84 bar into line 60.
  • the pressure-increase in this compression step is chosen between 30 bar and 150 bar, depending on the choices of respectively the separation pressure and the liquefaction pressure.
  • Part of the heat added during this compression step is removed from stream 60 against the ambient, for instance using an air cooler 61 or a water cooler.
  • the resulting ambient-cooled stream 70 is then led to the effluent stream heat exchanger 41 where it is cooled in indirect heat exchange with the cold overhead stream 40.
  • the cold stream 80 is then further cooled in one or more external cooling stages. This may include a pre-cooling stage, here depicted as heat exchanger 81.
  • a train of subsequent heat exchangers may be employed instead.
  • a pre-cooled stream 90 is then further cooled into liquefaction in a liquefaction unit (generally indicated by reference number 5) at least comprising a main cryogenic heat exchanger 91.
  • a main cryogenic heat exchanger 91 Any suitable type of heat exchanger may be employed.
  • a cryogenic heat exchanger 91 operated by a mixed refrigerant, of which light and heavy fractions are first autocooled in tubes running parallel to the pre-cooled stream (not shown) and then expanded to the shell side via inlet means 95 and 96 respectively.
  • the spent heavy and light fractions are drawn from the shell side of the main cryogenic heat exchanger 91 via outlet 97.
  • the spent refrigerant in line 97 can be recompressed to form a liquid, or, in case of a mixed refrigerant, a mixed vaporous light fraction and liquid heavy fraction.
  • the liquefaction pressure is chosen to exceed a pressure of at least 70, preferably at least 84 bar, more preferably above 86 bar.
  • the vapour in stream 60 may be in a supercritical condition.
  • the liquefied stream leaving the main cryogenic heat exchanger 91 via line 100 is further cooled in a flash step wherein the pressure is let down via a valve or liquid expander 101.
  • the pressure after expanding is about atmospheric.
  • Expansion heat is extracted from the liquefied stream, so that the temperature is further lowered to a temperature under which the liquefied product remains liquid at atmospheric pressure.
  • Flash gas 130 typically containing nitrogen and some methane, is separated from the stream 110 in flash tank 111.
  • a part of the flash gas 130 can be employed as fuel gas for providing energy to the liquefaction process.
  • the liquid part of stream 110 is discharged from the bottom of flash tank 111 in line 120. This can be stored and transported as LNG.
  • Table I gives an overview of the pressures and temperatures of a stream at various parts in an example process of Fig. 1. Also the mol% of methane is indicated.
  • the feed stream in line 10 of Fig. 1 comprised approximately the following composition: 85% methane, 6% ethane, 4% propane, 2% butanes, 1% C $ + and 2% N2 • Freezable components such as H2S, CO2 and H2O were previously removed.
  • FIG. 2 schematically depicts an alternative embodiment of the process according to the invention.
  • the feed stream 10 is expanded in an expander 12 to a pressure below 35 bar before entering the separator 31 as stream 25.
  • the compressor train 51 uses expansion energy from at least expander 12.
  • at least one compressor of the compressor train 51 is functionally coupled to the expander 12 thereby forming a so-called "compressor-expander scheme".
  • Additional compression power may however be provided to achieve a pressure above 84 bar.
  • the additional compressor motor power consumed by the compressor 51 is chosen close to or identical to the power required by the refrigerant compressors so that identical drivers can be employed for both purposes thereby providing cost and maintenance benefits.
  • Table II gives an indication of decrease in cooling duty in the heat exchangers for cooling and liquefaction of the natural gas using the process as described in Fig. 1 according to the present invention.
  • the same line-up as Fig. 1 was used, but - in contrast to the present invention - no heat exchanging took place in heat exchanger 41.
  • the present invention results in a significantly decreased cooling duty of about 10%.

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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)
  • Oil, Petroleum & Natural Gas (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Separation By Low-Temperature Treatments (AREA)

Abstract

The present invention relates to a method of liquefying a natural gas stream, wherein the natural gas stream (10) is provided at a pressure of 10-80 bar, supplied to a gas/liquid separator (31), and separated into a vaporous stream (40) and a liquid stream (30). The vaporous stream (40) is compressed to a pressure of at least 70, 84 bar heat exchanged against the vaporous stream (40), and liquefied to obtain a liquefied natural gas stream (100).

Description

METHOD AND APPARATUS FOR LIQUEFYING A NATURAL GAS STREAM
The present invention relates to a method of liquefying a natural gas stream.
Several methods of liquefying a natural gas stream thereby obtaining liquefied natural gas (LNG) are known. It is desirable to liquefy a natural gas stream for a number of reasons. As an example, natural gas can be stored and transported over long distances more readily as a liquid than in gaseous form, because it occupies a smaller volume and does not need to be stored at high pressures.
Examples of known methods of liquefying gas are disclosed in US 6 272 882 and DE 102 26 597 Al.
According to Figure 1 of DE 102 26 597 Al a natural gas stream having a pressure of 70-100 bar is expanded (Expander X) to a pressure range of 40-70 bar, cooled
(Heat Exchanger El) and fed to a Heavy Hydrocarbon (HHC) column (Tl) . A C2-rich fraction taken from the overhead of the HHC column is further cooled (E2) and fed to a further column (D) . The overhead stream of this further column (D) is pressurized (V) to a pressure in the range of 50-100 bar and subsequently liquefied.
A problem of the method according to DE 102 26 597 is that it is unnecessarily complicated. A further problem of the above method is that it needs a relatively high cooling duty in the heat exchanger (s) for liquefying the natural gas.
It is an object of the present invention to minimize the above problems .
It is a further object of the present invention to decrease the total duty of the heat exchangers used for cooling and liquefying the natural gas. It is an even further object of the present invention to provide an alternative method for liquefying a natural gas stream.
One or more of the above or other objects are achieved according to the present invention by providing a method of liquefying a natural gas stream, the method comprising the steps of:
(a) providing a feed stream containing natural gas at a pressure of 10-80 bar, preferably 10-50 bar; (b) supplying the feed stream provided in step (a) to a gas/liquid separator;
(c) separating the feed stream in the gas/liquid separator into a vaporous stream and a liquid stream, the vaporous stream being enriched in methane relative to the feed stream, and the liquid stream being reduced in methane relative to the feed stream;
(d) compressing the vaporous stream obtained in step (c) thereby obtaining a compressed stream having a pressure of at least 70, preferably at least 84 bar; (e) liquefying the compressed stream obtained in step (d) thereby obtaining a liquefied natural gas stream; wherein the compressed stream obtained in step (d) , before it is liquefied in step (e) , is heat exchanged against the vaporous stream obtained in step (c) , and wherein the pressure of the feed stream as provided in step (a) is not increased until the compressing in step (d) .
It has surprisingly been found that using the method according to the present invention, a significantly increased recovery of compounds heavier than methane can be obtained. An important advantage of the present invention is that this can be achieved in a surprisingly simple manner. A further advantage of the present invention is that an increased production of liquefied natural gas can be obtained using a given refrigeration power. Thus, for a given refrigeration power (e.g. using a given line-up comprising one or more cryogenic heat exchangers, compressors, etc.), the method according to the present invention provides more LNG than a known process. It has been found that according to the present invention increases in LNG product as high as 20% may be obtained, while keeping the refrigeration power constant.
It is noted that US 2004/0079107 Al discloses the heat exchanging of a compressed stream against a vaporous stream obtained from a distillation column. However, US 2004/0079107 Al teaches away from the present invention, as paragraphs [0032] and [0033] (while referring to Figure 4) of US 2004/0079107 Al suggest to perform the liquefaction at lower pressures. Thus according to US 2004/0079107 Al it is suggested to heat exchange the vaporous stream obtained from the distillation column against a compressed stream which is at a relatively low pressure, which is contrary to the present invention.
According to the present invention the natural gas stream may be any suitable gas stream to be liquefied, but is usually obtained from natural gas or petroleum reservoirs. As an alternative the natural gas may also be obtained from another source, also including a synthetic source such as a Fischer-Tropsch process.
Usually the natural gas stream is comprised substantially of methane. Preferably the feed stream comprises at least 60 mol% methane, more preferably at least 80 mol%, most preferably the feed stream comprises at least 90 mol% methane.
Depending on the source, the natural gas may contain varying amounts of hydrocarbons heavier than methane such - A - as ethane, propane, butanes and pentanes as well as some aromatic hydrocarbons. The natural gas stream may also contain non-hydrocarbons such as H2O, N2, CO2, H2S and other sulphur compounds, and the like. If desired, the feed stream containing the natural gas may be pre-treated before feeding it to the gas/liquid separator. This pre-treatment may comprise removal of undesired components such as CO2 and H2S, or other steps such as pre-cooling, pre-pressurizing or the like. As these steps are well known to the person skilled in the art, they are not further discussed here.
The gas/liquid separator may be any suitable means for obtaining a vaporous stream and a liquid stream, such as a scrubber, distillation column, etc. If desired, two or more gas/liquid separators may be present.
The person skilled in the art will readily understand that the increase in pressure of the vaporous stream may be performed in various ways, provided that a pressure of at least 70, preferably at least 84 bar is obtained. Preferably, the pressure in step (d) is increased by compressing the vaporous stream in a compressor, thereby obtaining a compressed stream. To this end one or more compressors may be used.
Also, the person skilled in the art will understand that the liquefaction of the pressurized vaporous stream may be performed in various ways, e.g. using one or more cryogenic heat exchangers.
Further the person skilled in the art will readily understand that after liquefaction, the liquefied natural gas may be further processed, if desired. As an example, the obtained LNG may be depressurized by means of a Joule-Thomson valve or by means of a cryogenic turbo- expander. Also, further intermediate processing steps between the gas/liquid separation and the liquefaction may be performed. Preferably in step (d) the pressure is increased to at least 86 bar, preferably at least 90 bar. Herewith the amount of LNG product obtained may be increased. As a result of the relatively high pressure used, the vaporous stream may be supercritical, depending on the prevailing pressure and the composition of the respective vaporous stream. Preferably the vaporous stream is supercritical, as this avoids phase changes in the liquefaction process. Further it is preferred that the vaporous stream obtained in step (c) has a C5"1" content of below 0.5 mol%, preferably below 0.1 mol%. This minimizes operating problems in the downstream liquefaction unit. With "C5"1" content" is meant the content of hydrocarbon components having five or more carbon atoms. Further it is preferred that the compressed stream obtained in step (d) is cooled, e.g. in an ambient heat exchanger. Further it is preferred that the compressed stream is heat exchanged against the vaporous stream obtained in step (c) . Also it is preferred that the feed stream, before supplying to the gas/liquid separator in step (b) , is expanded. Preferably the feed stream is expanded to a pressure < (below) 35 bar.
According to a particularly preferred embodiment of the method according to the present invention, an expander for expanding the feed stream is functionally coupled to a compressor for compressing the vaporous stream. As a result, the power generated by the expander is used at least partially for driving the compressor to which it is functionally coupled. Hereby, the expander and compressor form a so-called "compressor-expander scheme", as a result of which the energy consumption of the whole process is minimized. As the person skilled in the art will readily understand what is meant with a "compressor-expander scheme", this is not further discussed here.
In a further aspect the present invention relates to LNG product obtained by the method according to the present invention, in particular liquefied methane.
In an even further aspect the present invention relates to an apparatus suitable for performing the method according to the present invention, the apparatus at least comprising: - means for providing a feed stream containing natural gas at a pressure of 10-80 bar, preferably 10-50 bar; a gas/liquid separator for separating the feed stream into a vaporous stream and a liquid stream, the vaporous stream being enriched in methane relative to the feed stream, and the liquid stream being reduced in methane relative to the feed stream; a compressor for increasing the pressure of the vaporous stream obtained in the gas/liquid separator to a pressure of at least 70, preferably at least 84 bar, thereby obtaining a compressed stream; a heat exchanger for heat exchanging the compressed stream against the vaporous stream obtained from the gas/liquid separator; and a liquefaction unit for liquefying an effluent from the heat exchanger having a pressure of at least 70, preferably at least 84 bar, the liquefaction unit comprising at least one cryogenic heat exchanger.
Preferably, the apparatus further comprises an expander for expanding the feed stream. According to a particularly preferred embodiment, the compressor and expander are functionally coupled, thereby forming a so-called "compressor-expander scheme".
Hereinafter the invention will be further illustrated by the following non-limiting drawing. Herein shows: Fig. 1 schematically a process scheme in accordance with an embodiment of the present invention; and
Fig. 2 schematically a process scheme in accordance with another embodiment of the present invention. For the purpose of this description, a single reference number will be assigned to a line as well as a stream carried in that line. Same reference numbers refer to similar components.
Figure 1 schematically shows a base load liquefied natural gas (LNG) export process and an apparatus
(generally indicated with reference number 1) suitable for performing the same. A feed stream 10 containing natural gas is supplied to a gas/liquid separator 31 at a certain inlet pressure and inlet temperature. In the embodiment of Figure 1 the feed stream 10 is pre-cooled against a refrigerant in a heat exchanger 11. Typically, the inlet pressure to heat exchanger 11 will be between 10 and 80 bar (preferably < (below) 50 bar) , and the temperature will be close to ambient temperature, usually between 5 and 50 0C.
If desired the feed stream 10 may have been pre-treated before it is fed to the separator 31. As an example, the feed stream 10 may be expanded (as also shown in the embodiment of Figure 2 hereafter; in expander 12) .
As mentioned above, in the embodiment of Figure 1, the feed stream 10 is pre-cooled against a refrigerant in a heat exchanger 11, or in a train of heat exchangers, for instance comprising two or more heat exchangers operating at different refrigerant pressure levels. The pre-cooled feed stream in line 20 is at a pre-cooling temperature that is lower than the temperature in line 10. The pre-cooling temperature is chosen to form a partially condensed feed stream 20. Further, the pre- cooling temperature is chosen to optimise a subsequent separation step in separator 31.
As mentioned above, stream 20 is fed to the gas/liquid separator 31. There the feed stream in line 20 is separated into a vaporous overhead stream 40 and a liquid bottom stream 30. The overhead stream 40 is enriched in methane (and usually also ethane) relative to the feed stream 20.
The bottom stream 30 is generally liquid and usually contains some components that are freezable when they would be brought to a temperature at which methane is liquefied. Separator 31 can be a separator vessel or a distillation column such as a scrub column, depending on the separation required to remove freezable components from the feed stream. Typically the freezable components are CO2, H2S and hydrocarbon components having the molecular weight of pentane or higher. These freezable components may also at least partially have been removed from the feed stream before entering the separator 31. The bottom stream 30 may also contain hydrocarbons that can be separately processed to form liquefied petroleum gas (LPG) products.
Usually, the bottom stream 30 is subjected to one or more fractionation steps to collect various natural gas liquid products.
The overhead stream 40 is led through an effluent stream heat exchanger 41, where it is indirectly heated against a stream of about ambient temperature (stream 70) . Stream 50, which is discharged from the effluent stream heat exchanger 41 is then compressed via compressor 51 or a train of two or more compressors. The compressed stream is discharged at a pressure above 84 bar into line 60. The pressure-increase in this compression step is chosen between 30 bar and 150 bar, depending on the choices of respectively the separation pressure and the liquefaction pressure.
Part of the heat added during this compression step is removed from stream 60 against the ambient, for instance using an air cooler 61 or a water cooler. The resulting ambient-cooled stream 70 is then led to the effluent stream heat exchanger 41 where it is cooled in indirect heat exchange with the cold overhead stream 40. The cold stream 80 is then further cooled in one or more external cooling stages. This may include a pre-cooling stage, here depicted as heat exchanger 81. A train of subsequent heat exchangers may be employed instead.
A pre-cooled stream 90 is then further cooled into liquefaction in a liquefaction unit (generally indicated by reference number 5) at least comprising a main cryogenic heat exchanger 91. Any suitable type of heat exchanger may be employed. Here depicted is a cryogenic heat exchanger 91 operated by a mixed refrigerant, of which light and heavy fractions are first autocooled in tubes running parallel to the pre-cooled stream (not shown) and then expanded to the shell side via inlet means 95 and 96 respectively. The spent heavy and light fractions are drawn from the shell side of the main cryogenic heat exchanger 91 via outlet 97. The spent refrigerant in line 97 can be recompressed to form a liquid, or, in case of a mixed refrigerant, a mixed vaporous light fraction and liquid heavy fraction. Referring again to stream 60, the liquefaction pressure is chosen to exceed a pressure of at least 70, preferably at least 84 bar, more preferably above 86 bar. As a result, the vapour in stream 60 may be in a supercritical condition.
As a next step, the liquefied stream leaving the main cryogenic heat exchanger 91 via line 100 is further cooled in a flash step wherein the pressure is let down via a valve or liquid expander 101. Suitably the pressure after expanding is about atmospheric. Expansion heat is extracted from the liquefied stream, so that the temperature is further lowered to a temperature under which the liquefied product remains liquid at atmospheric pressure. Flash gas 130, typically containing nitrogen and some methane, is separated from the stream 110 in flash tank 111. A part of the flash gas 130 can be employed as fuel gas for providing energy to the liquefaction process. The liquid part of stream 110 is discharged from the bottom of flash tank 111 in line 120. This can be stored and transported as LNG.
Table I gives an overview of the pressures and temperatures of a stream at various parts in an example process of Fig. 1. Also the mol% of methane is indicated. The feed stream in line 10 of Fig. 1 comprised approximately the following composition: 85% methane, 6% ethane, 4% propane, 2% butanes, 1% C$ + and 2% N2 • Freezable components such as H2S, CO2 and H2O were previously removed.
TABLE I
Figure 2 schematically depicts an alternative embodiment of the process according to the invention. In this embodiment, the feed stream 10 is expanded in an expander 12 to a pressure below 35 bar before entering the separator 31 as stream 25.
Preferably, the compressor train 51 uses expansion energy from at least expander 12. To this end at least one compressor of the compressor train 51 is functionally coupled to the expander 12 thereby forming a so-called "compressor-expander scheme". Additional compression power may however be provided to achieve a pressure above 84 bar. Preferably, the additional compressor motor power consumed by the compressor 51 is chosen close to or identical to the power required by the refrigerant compressors so that identical drivers can be employed for both purposes thereby providing cost and maintenance benefits.
Table II gives an indication of decrease in cooling duty in the heat exchangers for cooling and liquefaction of the natural gas using the process as described in Fig. 1 according to the present invention. As a comparison the same line-up as Fig. 1 was used, but - in contrast to the present invention - no heat exchanging took place in heat exchanger 41. As shown in Table II the present invention results in a significantly decreased cooling duty of about 10%.
TABLE II
Figure imgf000013_0001

Claims

C L A I M S
1. Method of liquefying a natural gas stream, the method comprising the steps of:
(a) providing a feed stream containing natural gas at a pressure of 10-80 bar, preferably 10-50 bar; (b) supplying the feed stream provided in step (a) to a gas/liquid separator;
(c) separating the feed stream in the gas/liquid separator into a vaporous stream and a liquid stream, the vaporous stream being enriched in methane relative to the feed stream, and the liquid stream being reduced in methane relative to the feed stream;
(d) compressing the vaporous stream obtained in step (c) thereby obtaining a compressed stream having a pressure of at least 70, preferably at least 84 bar; (e) liquefying the compressed stream obtained in step (d) thereby obtaining a liquefied natural gas stream; wherein the compressed stream obtained in step (d) , before it is liquefied in step (e) , is heat exchanged against the vaporous stream obtained in step (c) , and wherein the pressure of the feed stream as provided in step (a) is not increased until the compressing in step (d) .
2. Method according to claim 1, wherein in step (d) the pressure is increased to at least 86 bar, preferably at least 90 bar.
3. Method according to claim 1 or 2, wherein the vapour stream obtained in step (c) has a C5"1" content of below
0.5 mol%, preferably below 0.1 mol%.
4. Method according to one or more of the preceding claims, wherein the compressed stream obtained in step (d) is cooled, before it is heat exchanged against the vaporous stream obtained in step (c) .
5. Method according to one or more of the preceding claims, wherein the feed stream provided in step (a), before supplying to the gas/liquid separator in step (b) , is expanded, preferably to a pressure < 35 bar.
6. Method according to claim 5, wherein an expander for expanding the feed stream is functionally coupled to a compressor for compressing the vaporous stream in step (d) .
7. Apparatus (1) for liquefying a natural gas stream, the apparatus at least comprising: means (10) for providing a feed stream containing natural gas at a pressure of 10-80 bar, preferably 10-50 bar; a gas/liquid separator (31) for separating the feed stream (10) into a vaporous stream (40) and a liquid stream (30) , the vaporous stream (40) being enriched in methane relative to the feed stream (10), and the liquid stream (30) being reduced in methane relative to the feed stream (10) ; a compressor (51) for increasing the pressure of the vaporous stream (40) obtained in the gas/liquid separator (31) to a pressure of at least 70, preferably at least 84 bar, thereby obtaining a compressed stream; a heat exchanger (41) for heat exchanging the compressed stream against the vaporous stream (40) obtained from the gas/liquid separator (31); and a liquefaction unit (5) for liquefying an effluent from the heat exchanger (41) having a pressure of at least 70, preferably at least 84 bar, the liquefaction unit (5) comprising at least one cryogenic heat exchanger (91) .
8. Apparatus (1) according to claim 7, wherein the apparatus further comprises an expander (12) for expanding the feed stream (10) before it is supplied to the gas/liquid separator (31).
9. Apparatus (1) according to claim 8, wherein the compressor (51) and expander (12) are functionally coupled.
10. Apparatus (1) according to one or more of the preceding claims 7-9, wherein no compressor is present between the means (10) for providing the feed stream at a pressure of 10-80 bar and the compressor (51) for increasing the pressure of the vaporous stream (40) .
PCT/EP2006/061470 2005-04-12 2006-04-10 Method and apparatus for liquefying a natural gas stream WO2006108821A1 (en)

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