Patent Grant
11340012
The present invention relates to improved refrigerant compositions and methods for liquefying gaseous streams, particularly gaseous streams consisting of or comprising hydrogen or helium.
The demand for liquid hydrogen production for e.g. clean energy applications is rapidly increasing. Thus, a significant upscaling of industrial hydrogen liquefiers is required to step up from the current largest state-of-the-art plants with a capacity in the range of 5 tpd to 10 tpd (upscaling factor 10 to 20). New large-scale hydrogen liquefaction plants with production capacities of, for instance, up to 150 tpd will require thermodynamically and economically efficient process designs. Specific energy consumption, and thus operational costs, has to be significantly reduced compared to state-of-the art plant and prior concepts, while limiting additional capital expenditures as well as utilizing process equipment and technology available today.
In current industrial hydrogen liquefiers, the hydrogen feed stream is precooled from ambient temperature to approximately 80 K by evaporating a liquid nitrogen stream at typically about 78 K. Liquid nitrogen is supplied, for example, from an onsite air separation unit, a nitrogen reliquefier or by liquid trailers. This plant design is economically effective for small to medium scale liquefiers. However, for higher liquefaction capacities, the liquid nitrogen stream supplied as a refrigerant will significantly increase the plant operating costs, thus reducing sharply the cost effectiveness of liquid hydrogen production.
In order to increase the energy-efficiency of the hydrogen feed precooling, closed loop refrigeration cycles can be designed for medium and large-scale liquefiers. Currently known conceptual designs for precooling cycles in hydrogen liquefiers show, however, deficiencies in either energy-efficiency, capital costs and/or process complexity e.g. rotating equipment count, refrigerant make-up system. Up to now, this has been a major limiting factor for upscaling hydrogen liquefaction plants from current maximum single train production rates.
Closed-loop nitrogen expander cycles as proposed in Ohlig et al. (“Hydrogen, 4. Liquefaction” Ullmanns's Encyclopedia of Industrial Chemistry, edited by F. Ullmann, Wiley-VCH Verlag, 2013) can reach precooling temperatures around or below 80 K, but are characterized by a relatively high number of additional rotating machines and a significantly lower thermodynamic efficiency compared to mixed-refrigerant cycles.
Currently, known mixed-refrigerant cycles, (U.S. Pat. No. 4,033,735, U.S. Pat. No. 5,657,643 and Bauer (StarLNG™: a Family of Small-to-Mid-Scale LNG Processes, Conference paper, 9th Annual Global LNG Tech Summit 2014: March 2014) for large industrial gas cooling processes, such as natural gas, can increase precooling efficiency but are designed for relatively high precooling temperatures, typically above 120 K, thus shifting the generation of the required cooling duty to the colder, more inefficient refrigeration cycle in a hydrogen liquefier. Additionally, prior conceptual designs for hydrogen liquefiers, such as in the IDEALHY study (2012, http://www.idealhy.eu), have proposed precooling refrigerant mixtures with a comparatively high number of fluid components (5 or more). In contrast to natural gas processing sites, these refrigerants have to be regularly imported to potential hydrogen liquefaction plant sites for inventory make-up and typically require additional storage vessels for each component, thus increasing operational complexity and handling.
Thus, it is the objective of the present invention to provide improved refrigerant compositions and a method for efficiently and economically liquefying gas streams, particularly suitable for large scales.
This objective is attained by the refrigerant composition according to claim 1 and the method according to claim 11.
According thereto, a refrigerant composition is provided, wherein the composition comprises an inert gas selected from nitrogen, argon, neon and a mixture thereof, and a mixture of at least two C1-C5 hydrocarbons. The refrigerant composition comprises four components, wherein a first component is nitrogen or nitrogen in a mixture with neon and/or argon, a second component is methane or argon, a third component is ethane or ethylene, and a fourth component is one of n-butane, isobutane, 1-butene, propane, propylene, n-pentane and isopentane.
The refrigerant composition of the invention is particularly useful for refrigerants that are designed to cool fluid streams from ambient temperature to lower temperatures in the range of 80 K to 125 K. This is achieved by pressurizing such refrigerants and expanding under cooling of the refrigerant, particularly to the above-mentioned temperature range, thereby producing cold. Particularly, such refrigerants may advantageously be used as precooling refrigerants in processes such as the liquefactions of gases such as hydrogen.
In certain embodiments, the refrigerant composition comprises an inert gas selected from nitrogen and nitrogen in a mixture with argon and/or neon, and further comprises a mixture of at least two C1-C5 hydrocarbons.
In certain embodiments, the C1-C5 hydrocarbon is selected from the group comprised of methane, ethane, ethylene, n-butane, isobutane, propane, propylene, n-pentane, isopentane and 1-butene.
In certain embodiments, the refrigerant composition comprises or consists of four components, wherein a first component is nitrogen, or nitrogen in a mixture with neon and/or argon, a second component is argon or methane, a third component is ethane or ethylene, and a fourth component is n-butane, isobutane, 1-butene, propane, propylene, n-pentane or isopentane.
In certain embodiments, the refrigerant composition comprises a fifth component, wherein the fifth component is argon, neon, n-butane, isobutane, 1-butene, propane, propylene, n-pentane or isopentane, provided that the fifth component is different from the fourth component or the second component, e.g. the fifth component can be n-butane, isobutane, propane, propylene or n-pentane if the fourth component is isopentane.
In certain embodiments, the refrigerant composition comprises a sixth component, wherein the sixth component is argon, neon, n-butane, isobutane, 1-butene, propane, propylene, n-pentane or isopentane, provided that the sixth component is different from the second component, the fourth component and fifth component, e.g. the sixth component can be isobutane, propane, propylene or n-pentane if the fourth component is isopentane and the fifth component is n-butane.
The refrigerant composition of the invention can be adapted depending on the designed precooling temperatures. Also, the refrigerant composition can be monitored and regulated by the plant make-up system in order to adapt the mixture composition to changing ambient and process conditions.
In certain embodiments, the first component is nitrogen, the second component is methane, the third component is ethane or ethylene, and the fourth component is isobutane, n-butane, isopentane or n-pentane. Such composition of the refrigerant of the invention is particularly useful if the cooling temperature to be achieved with the refrigerant is in the range 100 K and 120 K, and higher.
In certain embodiments, the third component is ethane. Such composition of the refrigerant of the invention is particularly useful if the intermediate temperature to be achieved in the precooling step is below or equal to approx. 100 K (±5 K). In certain embodiments, third component is ethylene. Such composition of the refrigerant of the invention is particularly useful if the cooling temperature to be achieved with the refrigerant is above approx. 100 K (±5 K).
In certain embodiments, the fourth component, and optionally the fifth component, is isobutane, 1-butene, propane, propylene or isopentane, provided that the fifth component is different from the fourth component. Such composition of the refrigerant of the invention is particularly useful if the cooling temperature to be achieved with the refrigerant is below approx. 100 K (±5 K).
In certain embodiments, the refrigerant composition comprises
In certain embodiments, the refrigerant composition comprises
In certain embodiments,
Such compositions of the refrigerant of the invention are particularly useful if the cooling temperature to be achieved with the refrigerant is between 100 K and 120 K, particularly between 100 K and 110 K.
In certain embodiments, the refrigerant composition consists of 11 mol. % nitrogen, 33 mol. % methane, 31 mol. % ethane and 25 mol. % n-butane. In certain embodiments, the refrigerant composition consists of 12 mol. % nitrogen, 32 mol. % methane, 31 mol. % ethane and 25 mol. % n-butane. In certain embodiments, the refrigerant composition consists of 14 mol. % nitrogen, 32 mol. % methane, 29 mol. % ethane and 25 mol. % isobutane. In certain embodiments, the refrigerant composition consists of 16 mol. % nitrogen, 31 mol. % methane, 27 mol. % ethane and 26 mol. % isobutane. In certain embodiments, the refrigerant composition consists of 10 mol. % nitrogen, 33 mol. % methane, 41 mol. % ethane and 16 mol. % pentane. In certain embodiments, the refrigerant composition consists of 11 mol. % nitrogen, 32 mol. % methane, 38 mol. % ethane and 19 mol. % isopentane. Such compositions of the refrigerant of the invention are particularly useful the cooling temperature to be achieved with the refrigerant is between 100 K and 120 K.
In certain embodiments,
In certain embodiments,
Such compositions of the refrigerant of the invention are particularly useful if the cooling temperature to be achieved with the refrigerant is between 90 K and 100 K
In certain embodiments, the refrigerant composition consists of 22 mol. % nitrogen, 30 mol. % methane, 24 mol. % ethane and 24 mol. % isobutane. In certain embodiments, the refrigerant composition consists of 17 mol. % nitrogen, 33 mol. % methane, 24 mol. % ethane and 26 mol. % isobutane. In certain embodiments, the refrigerant composition consists of 18 mol. % nitrogen, 29 mol. % methane, 36 mol. % ethane and 17 mol. % isopentane. In certain embodiments, the refrigerant composition consists of 18 mol. % nitrogen, 27 mol. % methane, 37 mol. % ethane and 18 mol. % isopentane. In certain embodiments, the refrigerant composition consists of 23 mol. % nitrogen, 30 mol. % methane, 12 mol. % ethane and 35 mol. % propane. Such compositions of the refrigerant of the invention are particularly useful if the cooling temperature to be achieved with the refrigerant is between 90 K and 100 K.
In certain embodiments, the refrigerant composition comprises
In certain embodiments, the refrigerant composition comprises
In certain embodiments,
Such compositions of the refrigerant of the invention are particularly useful if the cooling temperature to be achieved with the refrigerant is between 90 K and 100 K.
In certain embodiments,
Such compositions of the precooling refrigerant are particularly useful if the cooling temperature to be achieved with the refrigerant is between 85 K and 90 K.
In certain embodiments, the refrigerant composition consists of 20 mol. % nitrogen, 30 mol. % methane, 26 mol. % ethane and 24 mol. % 1-butene. In certain embodiments, the refrigerant composition consists of 20 mol. % nitrogen, 30 mol. % methane, 24 mol % ethane and 26 mol. % 1-butene. In certain embodiments, the refrigerant composition consists of 22 mol. % nitrogen, 29 mol. % methane, 11 mol. % ethane and 38 mol. % propane. Such compositions of the refrigerant of the invention are particularly useful if the cooling temperature to be achieved with the refrigerant is between 80 K and 90 K.
In certain embodiments,
Such compositions of the refrigerant of the invention are particularly useful if the cooling temperature to be achieved with the refrigerant is between 80 K and 90 K.
In certain embodiments, the refrigerant composition consists of 12.5 mol. % nitrogen, 38 mol. % argon, 25.5 mol. % ethane and 24 mol. % 1-butene. Such composition of the refrigerant of the invention is particularly useful if the cooling temperature to be achieved with the refrigerant is between 80 K and 90 K, particularly between 85 K to 90 K.
In certain embodiments, the first component is nitrogen in a mixture with neon and/or argon, the second component is methane, the third component is ethane or ethylene, and the fourth component is n-butane, isobutane, i-butene, propane, propylene, n-pentane or isopentane. Such composition of the precooling refrigerant is particularly useful if the intermediate temperature to be achieved in the precooling step is below 100 K.
In certain embodiments, the refrigerant composition comprises
In certain embodiments, the refrigerant composition comprises 18 mol. % to 23 mol. % nitrogen, and/or 27 mol. % to 29 mol. % methane, and/or 24 mol. % to 37 mol. % ethane, and/or 18 mol. % to 24 mol. % isopentane or isobutane, provided that the sum of the concentrations of the abovementioned components does not exceed 100 mol %. Such composition of the refrigerant of the invention is particularly useful if the cooling temperature to be achieved with the refrigerant is around 100 K.
In certain embodiments, the refrigerant composition consists of 18 mol. % nitrogen, 27 mol. % methane, 37 mol. % ethane and 18 mol. % isopentane. Such composition of the refrigerant of the invention is particularly useful if the cooling temperature to be achieved with the refrigerant is around 100 K.
In certain embodiments, the refrigerant composition consists of 23 mol. % nitrogen, 29 mol. % methane, 24 mol. % ethane and 24 mol. % isobutane. Such composition of the refrigerant of the invention is particularly useful if the cooling temperature to be achieved with the refrigerant is around 100 K.
In certain embodiments, the refrigerant composition consists of 22 mol. % nitrogen, 29 mol. % methane, 28 mol. % ethane, 12 mol. % isobutane and 9 mol. %) isopentane. Such composition of the refrigerant of the invention is particularly useful if the cooling temperature to be achieved with the refrigerant is around 100 K.
According to a further aspect of the invention, the use of the refrigerant composition of the invention, particularly as a precooling refrigerant, in the liquefaction of a gaseous substance is provided.
In certain embodiments, the gaseous substance is selected from the group comprised of hydrogen and helium.
According to another aspect of the invention, a method for liquefaction of a feed gas stream is provided. The method comprises the steps of:
The term boiling temperature refers to the temperature at which the gas liquefies or begins to liquefy. The boiling temperature is dependent on the pressure of the gas.
In certain embodiments, the feed gas is selected from hydrogen and helium. The feed gas may comprise hydrogen. The feed gas may comprise helium.
In certain embodiments, the feed gas stream consists of hydrogen or helium.
Particularly, if the gas to be liquefied is hydrogen, ortho hydrogen comprised within the feed gas stream (typically about 75%) is preferably converted to higher para hydrogen fractions preferably before liquefaction of the feed gas stream to avoid that the exothermic ortho to para reaction takes place in the liquid product possibly resulting in an undesired partial vaporization of the liquid hydrogen product during storage and transport.
In certain embodiments, the precooled feed gas stream is cooled from the intermediate temperature to a temperature below the boiling temperature or the critical temperature of the gas by at least a first closed cooling cycle with a first cooling refrigerant, particularly in a first cooling zone, wherein the first cooling refrigerant is expanded, thereby producing cold.
In certain embodiments, the first refrigerant comprises or consists of hydrogen and/or helium.
In certain embodiments, the first refrigerant is provided with a high pressure, expanded to low pressure in an expansion device. The expansion device is preferably: a turbo expander, a throttle valve or a turbo expander and a throttle valve. The expanded first refrigerant and the precooled feed gas stream may be guided such that heat can indirectly be transferred between the expanded first refrigerant and the precooled feed gas stream, thereby preferably cooling the precooled feed gas stream below the boiling temperature or the critical temperature of the gas comprised within the feed gas stream. The expanded refrigerant may be compressed to high pressure yielding the first refrigerant.
In certain embodiments, the precooled feed gas stream is cooled from the intermediate temperature to a first temperature by a second closed cooling cycle with a second cooling refrigerant, particularly in a second cooling zone, wherein the second cooling refrigerant is expanded, thereby producing cold, and the cooled feed gas stream is further cooled from the first temperature to the temperature below the boiling temperature or the critical temperature of the gas comprised within the feed gas stream by the first closed cooling cycle.
In certain embodiments, the second refrigerant comprises or consists of neon and/or hydrogen.
In certain embodiments, the second refrigerant is provided with an initial high pressure, and is then expanded to low pressure in: an expansion device, preferably: a turbo expander; a throttle valve; in two turbo expanders; or in a turbo expander and a throttle valve The expanded second refrigerant and the precooled feed gas stream may be guided such that heat can indirectly be transferred between the expanded second refrigerant and the precooled feed gas stream, (preferably cooling the precooled feed gas stream to the first temperature) yielding a cooled feed gas stream. The expanded second refrigerant may be compressed to high pressure yielding the second refrigerant. The cooled feed gas stream and the expanded first refrigerant stream may be guided such that heat can indirectly be transferred between the cooled feed gas stream and the expanded first refrigerant stream, thereby preferably cooling the cooled feed gas to a temperature equal to or below the boiling temperature or the critical temperature of the gas comprised within the feed gas stream.
In certain embodiments, the first cooling zone is arranged within a cooling heat exchanger or one or more blocks of the cooling heat exchanger. In certain embodiments, the second cooling zone is arranged within another cooling heat exchanger or within one or more another blocks of the aforementioned cooling heat exchanger. In certain embodiments, the cooling heat exchanger is a plate heat exchanger.
In certain embodiments, the intermediate (precooling) temperature is in the range of 80 K to 125 K. In certain embodiments, the intermediate temperature is in the range of 80 K to 120 K. In certain embodiments, the intermediate temperature is in the range of 85 K to 120 K. In certain embodiments, the intermediate temperature is in the range of 90 K to 120 K, particularly in the range 90 K to 110 K, most particularly 95 K to 105 K. In certain embodiments, the intermediate temperature is 100 K. In certain embodiments, the intermediate temperature is in the range of 120 K to 150 K.
In certain embodiments, the feed gas stream and other cooling down refrigerant streams (such the above mentioned first refrigerant stream and/or second refrigerant stream) are precooled to the intermediate temperature in a precooling zone. In certain embodiments, the precooling zone is located within an at least one precooling heat exchanger or in one or more other blocks of the abovementioned cooling heat exchanger. In certain embodiments, the at least one precooling heat exchanger is a plate heat exchanger or a coil-wound heat exchanger.
In certain embodiments, the feed gas stream comprises hydrogen and is precooled to an intermediate temperature in the range 80 K to 120 K, yielding the precooled feed gas stream, and the precooled feed gas stream is brought into contact with a catalyst being able to catalyse the ortho to para conversion of hydrogen. In certain embodiments, the catalyst is or comprises hydrous ferric oxide. In certain embodiments, the catalyst is arranged within a heat exchanger in which the feed gas stream is precooled. The catalyst may be arranged within the at least one precooling heat exchanger or the one or more blocks of the above-mentioned cooling heat exchanger.
In certain embodiments, residual impurities, particularly nitrogen, are removed from the precooled feed gas stream before contacting the precooled feed stream with the above-mentioned catalyst, particularly by means of an adsorber. In certain embodiments, an adiabatic or isothermal ortho-para catalytic converter vessel is placed directly downstream or within the adsorber, wherein normal hydrogen comprised within the feed gas stream is converted in a first step to a para-content near the equilibrium at the intermediate temperature, e.g. 39% at 100 K).
In certain embodiments, the precooling step comprises the steps of:
In the above described precooling step, the step of guiding the precooling stream and the feed gas stream may include guiding the expanded precooling refrigerant stream, the feed gas stream and other refrigerant streams (e.g. high pressure precooling refrigerant as well as other cold-cycle refrigerant streams such as the above mentioned first and second refrigerant) such that heat can indirectly be transferred between the expanded precooling refrigerant stream and the other streams, thereby particularly cooling the feed gas stream as well as other cooling down streams to the intermediate temperature.
The term “indirectly heat transfer” in the context of the present invention refers to the heat transfer between at least two fluid streams that are spatially separated such that the at least two fluid streams do not merge or mix but are in thermal contact, e.g. two fluid streams are guided through two cavities and both streams do not mix, but heat can be transferred via the wall or the plate, for example of a plate heat exchanger, wherein the cavities are separated from each other by a wall or plate.
In certain embodiments, the first pressure is in the range of 20 bar(a) to 80 bar(a), more particularly in the range of 30 bar(a) to 60 bar(a), most particularly in the range of 40 bar(a) to 60 bar(a).
In certain embodiments, the first pressure is in the range of 60 bar(a) to 75 bar(a). In certain embodiments, the second pressure is in the range of 1.1 bar(a) to 10 bar(a), more particularly in the range of 1.1 bar(a) to 8 bar(a), most particularly in the range of 2 bar(a) to 6 bar(a).
In certain embodiments, the expanded precooling refrigerant stream has a temperature in the range of 80 K to 150 K, preferably in the range of 80 k to 120 K, more preferably in the range of 90 K to 120 K, more preferably in the range of 90 K to 110 K, most preferably in the range of 95 K to 105 K. In certain embodiments, the expansion device is a throttle valve.
In certain embodiments, compressing the precooling refrigerant comprises the steps of:
In certain embodiments, the expanded precooling refrigerant stream is compressed in at least two compressor stages or compressors, optionally with intercooling. Alternatively, the precooling refrigerant is compressed in the two phase region after intercooling with a pump and a phase separator between the compressor stages or the compressor stages, wherein as described above liquid phases and vapour phases of the precooling refrigerant stream are separately compressed. Alternatively, all liquid phases are unified and compressed together.
The intermediate pressure is designed between the low level, particularly the second pressure, and high pressure level, particularly the first pressure. In certain embodiments, the intermediate pressure is designed such that a liquid-vapour two-phase flow is generated at the compressor discharge after intercooling. In certain embodiments, the intermediate pressure is in the range of 10 bar(a) and 30 bar(a).
In certain embodiments, the precooling refrigerant stream is additionally separated into a mainly gaseous phase and a mainly liquid phase. The mainly gaseous phase and the mainly liquid phase may be separately expanded, preferably at different temperatures levels. The mainly gaseous phase and the mainly liquid phase may be guided with the feed gas stream, particularly in separate heat exchangers or separate heat exchanger blocks. In certain embodiments, the mainly gaseous phase and/or the mainly liquid phase are expanded in a throttle valve. In certain embodiments, both vapour and liquid phase are separately guided against the feed gas stream in the precooling zone.
In certain embodiments, the feed gas stream is provided with a pressure above the critical pressure of the gas comprised within the feed gas stream. In certain embodiments, the feed gas stream is provided with a pressure in the range of 15 bar(a) to 75 bar(a). In certain embodiments, the feed gas stream is provided with a pressure in the range of 25 bar(a) to 50 bar(a).
In certain embodiments, the cooled feed gas stream is expanded in an expansion device, and is thereby cooled. In certain embodiments, the expansion device is a turbo-expander or a throttle valve. In certain embodiments, the expansion device is a combination of a turbo-expander and a throttle valve. In certain embodiments, the cooled feed gas stream is expanded in the expansion device to a storage pressure, wherein particularly the storage pressure is in the range of 1 bar(a) to 3.5 bar(a), more particularly in the range of 1.8 bar(a) to 2.5 bar(a), even more particularly equal or close to the ambient pressure.
In the following, further features and advantages of the present invention as well as preferred embodiments are described with reference to the Figures, wherein
The present invention relates to novel refrigerant mixtures and compositions which have been particularly optimized for energy and cost efficient hydrogen precooling in hydrogen liquefiers. The refrigerant mixtures are particularly designed for closed-loop Joule-Thomson refrigeration cycles for large-scale industrial hydrogen liquefaction plants. The refrigerant mixtures are optimized for a low number of fluid components, preferably up to 4, and particularly for low-temperature cooling in the range between 80 K and 120 K, particularly between 90 K and 110 K. The mixtures have been designed for clog-free plant operation with margins to potential mixture or component freeze out (solidification) e.g. also through selected and effective melting-point depression.
The new proposed refrigerant mixtures and compositions allow a precooling cycle design and operation with comparatively low capital costs, industrially sound equipment e.g. heat exchanger size, and with reduced operational complexity. Compared to known technology and conceptual design for large-scale hydrogen liquefiers, the novel precooling refrigerant mixtures can reduce specific energy consumption of the liquefier by as much as 30%, thus enabling an economical production of liquid hydrogen on a large-scale. The present invention is used in the step of precooling the hydrogen feed gas stream as well as the precooling of other refrigerant streams to an intermediate temperature yielding a precooled feed gas stream. The invention is particular advantageous when, the intermediate temperature is in the range of 80 K to 150 K.
The novel refrigerant mixtures and compositions are used to provide precooling duty in a closed-loop refrigeration cycle e.g. in highly efficient single mixed-refrigerant (MR) cycles. The MR compositions in this invention have been optimized for hydrogen precooling temperatures particularly between 80 K and 120 K, thus differentiating itself from other large-scale industrial applications with warmer cooling temperatures, as natural gas liquefaction.
In the following the use of the refrigerant composition as a precooling refrigerant is exemplary illustrated in a process for hydrogen liquefaction. In other words the feed gas in the illustrative embodiments below comprises hydrogen. It will be appreciated that the invention includes embodiments in which the feed gas comprises helium, in accordance with the claims and statements above.
Hydrogen Cooling and Liquefaction:
A normal hydrogen (25% para) feed gas stream 11 from a hydrogen production plant is fed to the liquefaction plant 100 with a feed pressure above 15 bar(a), e.g. 25 bar(a), and a feed temperature near ambient temperature, e.g. 303 K. The feed stream 11 with a mass flow rate above 15 tpd, e.g. 100 tpd, is optionally cooled down between 283 K and 308 K, e.g. 298 K, with a cooling water system 75 or air coolers before entering the precooling cold-box 78 through plate-fin heat exchanger 81.
The hydrogen feed 11 is cooled in the aforementioned heat exchanger 81 to the lower precooling temperature T-PC, e.g. 100 K, by the warming-up the low pressure streams of the single mixed-refrigerant cycle 41 and the cold hydrogen refrigeration cycle (26 and 33). At the outlet of the heat exchanger 81, residual impurities are removed from the precooled hydrogen feed gas 12 to achieve a purity of typically 99.99% in the adsorber vessels 76, 77 by physisorption. The feed gas 12 enters the adsorption unit 76, 77 at the temperature T-PC, e.g. 100 K, which can thus be designed at about 20 K higher than in prior known hydrogen liquefier applications. This allows to shift the start of the catalytic ortho-para conversion to higher temperatures, e.g. 100 K, which is thermodynamically convenient.
After the feed gas purification 76, 77, the precooled feed gas stream 12 is routed back to the heat exchanger through 81 the catalyst filled passages (hatched areas in
The precooled feed gas stream 12 enters the vacuum-insulated liquefier cold-box 79 with T-PC (between 90 K and 120 K, e.g. 100 K). The feed stream 12 is subsequently cooled and liquefied as well as being catalytically converted to higher hydrogen para-fractions (hatched areas in
The hydrogen gas feed stream 11 from battery-limits may be further compressed e.g. from 25 bar(a) to higher pressures, e.g. 75 bar(a), to increase process efficiency and to reduce volumetric flows and equipment sizes by means of a one or two stage reciprocating piston compressor at ambient temperature, or a one stage reciprocating piston compressor with cold-suction temperatures after precooling in the heat exchanger 81 or an ionic liquid piston compressor.
Alternatively, an adiabatic ortho-para catalytic converter vessel may be used in the precooling cold box 78 to pre-convert normal-hydrogen (25%) para to a para-fraction near equilibrium in the feed gas stream 12 at the outlet of adsorber 76, 77, before routing the feed gas stream 12 back to the heat exchanger 81.
Detailed Description of the Single Mixed-Refrigerant Precooling Cold Cycle
A low pressure mixed refrigerant stream 42 is routed through suction drum 71 to avoid that entrained liquid droplets from the warmed-up refrigerant stream arrive to the suction side of compressor of stage one 63a of the compressor 63. The MR composition and the discharge pressure of the resulting refrigerant stream 43 (particularly in the range of 10 bar(a) to 25 bar(a)), after at least one compression stage, are optimized to produce the aforementioned stream 43 with a liquid fraction after intercooling. This reduces the mass-flow of refrigerant 43 that has to be compressed in stage two 63b of the compressor 63. The intercooled refrigerant stream 43 is separated into a liquid mixed refrigerant stream 45 that is pumped to the high pressure (particularly in the range of 30 bar(a) and 70 bar(a)) and into a vapour refrigerant stream 44, which is compressed to high pressure (particularly in the range of 25 bar(a) and 60 bar(a)) by the second stage 63b of compressor 63. Both the vapour 44 and the liquid stream 45 are mixed to a two-phase high pressure mixed-refrigerant stream 41 after compression 63. The first vapour stream 44 may be additionally separated into a second liquid phase and a second vapour phase, wherein preferably the first liquid phase 45 and the second liquid are unified, pumped together to high pressure and afterwards unified with the second vapour phase before entering the precooling cold box 78. Alternatively, the low pressure mixed refrigerant stream may be compressed by more than two stages. If compression and after-cooling results in the formation of a liquid phase, additionally phase separators may be arranged between the compressor stages.
The two-phase high pressure mixed-refrigerant stream 41 enters the precooling cold-box 78 passing through the heat exchanger 81, where it is precooled to the lower precooling temperature of 100 K. A Joule-Thomson valve 64 expands the precooled mixed-refrigerant stream 41 to an expanded mixed refrigerant stream 42 that is characterized by an optimized low pressure level, particularly between 1.5 bar(a) and 8 bar(a). The refrigerant mixture of the high pressure mixed refrigerant stream 41 is designed to cool down from the temperature T-PC by at least 2.5 K, e.g. 96 K, through the Joule-Thomson expansion. The mixture temperature decrease is designed to maintain a feasible temperature difference between warming up and cooling down streams in the heat exchanger 81 as well as to assure that no component freeze-out occurs in the refrigerant mixture.
Additionally, the two-phase high pressure mixed-refrigerant stream 41 may be further separated into a vapour 41a and a liquid phase 41b, wherein the liquid phase 41b may be additionally pumped to high pressure and unified with the vapour phase 41b before entering the precooling cold box 78. Alternatively, the vapour stream 41a of the above mentioned additional separation is guided through the heat exchanger 81 and an additional heat exchanger 81a or through two separate blocks 81, 81a of heat exchanger 81 in the precooling cold-box 78, expanded in a throttle valve 64b and guided again through both exchangers or blocks 81, 81a, whereby the liquid stream 41b of the additional separation is guided through the additional heat exchanger 81a, expanded in a throttle valve 64a and guided again through the additional exchanger 81a.
Alternatively as depicted in
Particularly, the vapour stream 41a may be merged after passing the heat exchanger 81 and expansion in the throttle valve 64b with the liquid stream 41b after passing the additional heat exchanger 81a and expansion in the throttle valve 64a, wherein the so merged expanded mixed-refrigerant stream 42 is then guided through the additional heat exchanger 81a.
The MR composition can be regulated and controlled by the make-up system to adapt the mixture composition to ambient conditions and changed process conditions. The mixed-refrigerant is compressed in a two-stage MR turbo-compressor with interstage water cooling to decrease power requirement.
Alternatively, in a very simplified configuration, the low pressure refrigerant stream 42 can be compressed within an at least two-stage compression 63 with inter-stage cooling and the refrigerant composition can be designed to avoid the appearance of a liquid fraction after the first compression stage 63a. Advantageously, no liquid pumps and no phase separator are required. However, a lower efficiency is expected.
Low temperature precooling is efficiently achieved with a refrigerant mixture optimized specifically for hydrogen liquefaction, wherein the refrigerant preferably contains only four refrigerant components to maintain a manageable plant makeup system. A preferred mixture composition for a precooling temperature in the range of 90 K to 100 K consists of 18 mol. % nitrogen, 27 mol. % methane, 37 mol. % ethane and 18 mol. % isopentane. Ethylene may replace the ethane component for reasons of refrigerant availability and cost. For precooling temperatures between 90 K and 100 K, iso-butane may be replaced by 1-butene, iso-pentane, propane or propylene The mixture of the mixed-refrigerant may be adapted depending on the precooling temperatures. Accordingly, the mixture may contain nitrogen, methane, ethylene, and n-butane, isobutane, propane, propylene isopentane, iso-butane and/or n-pentane for precooling temperatures between 100 K and 120 K (or higher).
For precooling temperatures above 85 K, the mixture may contain nitrogen, argon, neon, methane, ethane, propane, propylene, 1-butene.
Also alternatively, the hydrogen feed stream 11 may be precooled to temperatures above 120 K, wherein in this case the mixed-refrigerant preferably contains nitrogen, methane, ethylene, n-butane.
For slightly higher process efficiencies, a fifth or more refrigerant mixture component(s) can be added to the refrigerant mixture: iso-butane, iso-pentane, 1-butane, argon, neon, propane or propylene for precooling temperatures between 90 K and 100 K, or n-butane, iso-butane, iso-pentane, propane, propylene or pentane for the precooling temperature T-PC, particularly above 100 K, and additionally n-pentane, for precooling temperatures above 110 K.
Additionally, conventional refrigeration units (chiller), e.g. vapour compression refrigerators, operated with e.g. propane, propylene or CO2, can be placed to cool down the high pressure lines 11, 21, 41 from ambient temperature, downstream the respective water coolers 75, to increase the overall energy-efficiency of the plant. Chiller(s) can be placed in the Single Mixed-Refrigerant stream 41 and/or the Hydrogen Cold Refrigeration cycle stream 21 and/or the Feed Hydrogen stream 11.
Detailed Description of the Main Cooling High Pressure-Hydrogen Cycle
The high pressure hydrogen (first refrigerant) stream 21 with a pressure of at least 25 bar(a), particularly 30 bar(a) to 70 bar(a) enters the precooling cold-box 78 and is precooled by the warming up streams 42, 33, 26 in the heat exchanger 81 to the precooling temperature T-PC. At the inlet of the liquefier cold-box 79, the first refrigerant stream 21 is further precooled by the warming up streams of the cold hydrogen refrigeration cycle (33 and 26). The high pressure stream 21 is then separated in at least three turbine-strings, at different temperature levels, to generate cooling by nearly isentropic expansions (polytropic) in min. five turbine-expanders. In the illustrated example, seven turbine-expanders are employed (51 to 57) in to four partial streams 22, 23, 24, 2522, 23, 24, 25 which are routed through four turbine strings. The turbines 51 to 57 within the high-pressure process are designed with rotational speeds and frame-sizes that are industrially feasible and allow the partial recovery of process energy e.g. by the means of turbine brakes coupled with a turbo-generator to produce electricity and thus increase the total plant energy-efficiency. Alternatively, each of the above mentioned turbine strings may comprise only one turbo-expander, respectively, wherein the respective stream is directly expanded to low or medium pressure.
In the preferred invention example, the high pressure hydrogen flow 21 is first separated after being cooled in a heat exchanger 82. One fraction, or partial stream (also referred to as a fourth partial stream) 25 is routed to a first turbine string (57 and 56), in which it is expanded in two-stages from high pressure to a medium pressure to form a medium pressure (fourth partial) stream 32, particularly in the range 6 bar(a) to 12.9 bar (a), more particularly in the range of 7 bar (a) to 11 bar(a), e.g. 9 bar(a), to achieve high isentropic efficiencies with moderate turbine rotational speeds. This medium pressure stream 32 provides cooling duty to the cooling down streams 12, 21 The remaining high pressure flow fraction is subsequently cooled in heat exchanger 83 to the temperature of a second turbine string. A further partial stream (also referred to as a third partial stream) 24 is then separated and expanded in two-stages (55 and 54) to the above-mentioned medium pressure level to form a partially expanded stream 31. This partially expanded (third partial) stream 31 is warmed up and mixed with the above-mentioned medium pressure stream 32 in order to provide additional cooling to duty to the cooling down streams 12, 21. The turbine strings for the streams 25 and 24 can, alternatively, be designed with intermediate cooling between the two expansion stages.
A further remaining high pressure flow fraction, or partial stream (also referred to as the second partial stream) 23 routed to a third turbine string after being further cooled down by the warming up streams in heat exchanger(s) 85, 86. The following process feature is special to this hydrogen liquefaction process: the second partial stream 23 is expanded in turbo-expander 53 to an intermediate pressure between medium pressure and high pressure, to produce an intermediate pressure stream 29. The resulting intermediate pressure stream 29 preferably has a temperature above the critical temperature of the refrigerant, e.g. 34 K to 42 K. The intermediate pressure stream 29 is then re-warmed slightly in a further heat exchanger 88 before being expanded again in turbo-expander 52 to the medium pressure level yielding a medium pressure (first partial) stream 30. In this way, cooling with the third turbine string is generated at two different pressures (medium and intermediate pressure) and two different temperature levels. The heat exchanger enthalpy-temperature curve between the cooling down and warming up streams in a critical temperature range, e.g. 30 K to 50 K, can, hence, be matched more closely. This can reduce exergetical losses in the heat exchanger. This new process configuration is particularly beneficial for hydrogen feed cooling since: depending on the pressure, the specific isobaric heat capacity of the hydrogen feed stream possesses steep gradients in the region close to its critical temperature (particularly between 30 K and 50 K). Alternatively in an embodiment not shown, the third turbine string for the second partial stream 23 can be designed analogous to first and second turbine strings 25 and 24, with no intermediate warming-up after the first turbine, or with a slight cooling down between the expanders.
The medium pressure stream 30 provides cooling duty to the cooling down streams in the heat exchanger 86 to 89 up to the temperature of turbine outlet 54, where it is mixed with the medium pressure stream 31 to form a mixed stream. The mixed stream is warmed approximately to the temperature of the turbine 56 outlet (between the precooling temperature and the temperature of cooled feed stream 13 at the cold end of the heat exchanger 89, where it is further mixed with the medium pressure stream 32. The total medium pressure hydrogen flow 33 is warmed up in the heat exchangers 84 to 81 to a temperature close to ambient temperature, thereby providing additional cooling duty to the cooling down streams 11, 21, 41.
The outlet temperature and pressure of turbo-expander 52 are optimized in combination with the cold-end hydrogen cycle. The temperature of the medium pressure stream 30 at the turbine outlet is the cold-end temperature T-CE. For the newly proposed high pressure cycle, optimal cold-end temperatures T-CE for the high pressure cycle are set between 28 K and 33 K, particularly between 29 K and 32 K, for a dry-gas turbine discharge and an optimal MP1 pressure level, particularly in the range of 6 bar(a) and 12.9 bar(a), more particularly between 7 bar(a) and 11 bar(a), at the outlet of the turbo-expander 52 (medium pressure level between 7 bar(a) and 11 bar(a)). The warmed-up stream 33 is mixed with the compressed low pressure stream 26 from the compressor 61 to produce a mixed stream 34. The mixed stream 34 is compressed from medium pressure level in e.g. one or preferably two parallel running 100% reciprocating piston compressors 62, or alternatively three parallel running 50% reciprocating piston compressors to the high pressure level between 30 bar(a) and 75 bar(a). Temperature T-CE, medium and high pressure levels are optimized in function of precooling temperature TPC and liquid hydrogen production rate (feed mass flow rate). Piston compressors 61 and 62 are designed with at least two intercooled stages each (three stages preferred).
Compared to prior known technology, this high pressure configuration with significantly higher turbine outlet pressure levels (medium and high) yields moderate effective volumetric flows at the suction of compressor 62, thus enabling the design of mechanically viable frame-sizes for the hydrogen piston compressor, even for very large liquefaction capacities e.g. up to 150 tpd (with two parallel compressors).
At the cold end, the remaining high pressure hydrogen flow fraction, the first partial stream 22 in the cold-cycle provides the cooling for the final liquefaction and ortho-para conversion of the feed stream. The high pressure hydrogen refrigerant in the first partial stream 22 is expanded from high pressure to low pressure in at least one turbine string though at least one turbo-expander e.g. 51.
If the turbo-expander 51 is to be designed with a dry-gas discharge, high pressure stream 22 is expanded from high pressure to an intermediate pressure, above the critical pressure, e.g. 13 bara, or to a pressure below, e.g. in the range of 5 bar(a) to 13 bar(a), if no two-phase is to be generated within the turbine 51 or at the outlet of the turbine 51. Subsequently, the cooled stream is expanded through a Joule-Thomson throttle valve 59 into a gas-liquid separator 74. For a turbo-expander with allowed two-phase discharge, e.g. a wet expander, the high pressure stream 22 can be expanded directly to low pressure level. The low pressure stream 26 stream is warmed-up to near ambient temperature providing cooling duty to the cooling down streams 11, 12, 21, 41 in the precooling and liquefier cold-box. The low pressure stream 26 is then compressed in one multistage reciprocating piston compressor 61 with interstage cooling.
The hydrogen feed stream 12 is cooled by the warming up cold low pressure stream 26 down to a temperature equal to the high pressure stream 22, e.g. 29.5 K, and is catalytically converted to a para-fraction slightly below the equilibrium para-fraction. The cooled feed stream 13 is then expanded by the means of at least one turbo-expander 58 from feed pressure to an intermediate pressure e.g. 13 bar(a) or lower. Subsequently, the expanded and cooled feed stream is further expanded through the Joule-Thomson throttle valve 60 to the low pressure level that is required for final product storage pressure e.g. 2 bar(a) and particularly further cooled by the low pressure stream 26.
For turbo-expanders allowing a two-phase discharge, the high pressure feed stream 13 can be directly expanded into the two-phase region to the product storage pressure e.g. 2 bar(a). For shaft power around 50 kW or above, as in large-scale liquefiers with e.g. 100 tpd capacity, a turbo-expander with energy-recovery via a turbo-generator can be employed to raise the plant energy-efficiency. Alternatively, a cold liquid piston expander can be employed to directly expand the feed stream from the intermediate pressure level, e.g. 13 bar(a), to the low pressure level near the final product storage pressure. In either case, the two-phase hydrogen feed stream 14 is finally cooled and can be further catalytically converted in the last part of plate-fin heat exchanger 91 with the aid of the warming-up low pressure cold-cycle refrigerant stream 26.
With this configuration, a liquid hydrogen product stream 15 at the outlet can be generated as saturated liquid or even subcooled liquid. A final para-fraction of the liquid product stream 15 above 99.5% can be reached if desired.
The method of the invention offers the following advantages:
In summary:
| Number | Date | Country | Kind |
|---|---|---|---|
| 15003069 | Oct 2015 | EP | regional |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2016/075914 | 10/27/2016 | WO | 00 |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
| WO2017/072221 | 5/4/2017 | WO | A |
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| Number | Date | Country | |
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| 20180320957 A1 | Nov 2018 | US |
