Patent Grant
8181481
This application claims priority from European Patent Application No. 05111197.9, filed on Nov. 24, 2005, which is incorporated herein by reference.
The present invention relates to a method and apparatus for cooling a stream, in particular a hydrocarbon stream such as natural gas.
In a known refrigerant circuit used in a method for cooling a hydrocarbon stream, e.g. in order to produce an LNG stream, the refrigerant is successively compressed in a compressor arrangement, cooled against e.g. water or air in a first heat exchanger, expanded and evaporated in a second heat exchanger (usually a cryogenic heat exchanger) where the refrigerant cools at least the natural gas stream to be cooled. The spent refrigerant leaving the second heat exchanger is again compressed, cooled and so on.
An example of a known method for cooling a hydrocarbon stream is disclosed in U.S. Pat. No. 5,826,444. U.S. Pat. No. 5,826,444 relates to a process and to a device allowing to liquefy a fluid or a gaseous mixture consisting at least partly of a mixture of hydrocarbons, for example natural gas.
The compressor arrangement used for compressing the refrigerant in the known refrigerant circuits usually comprises only one or more centrifugal compressors and no axial compressors, due to the fixed optimal pressure ratio of an axial compressor.
The above is even more true in the liquefaction of a natural gas stream using a mixed refrigerant evaporating in multiple cryogenic heat exchangers at multiple pressure levels in the refrigerant cycle, thereby resulting in various refrigerant streams at different pressure levels to be cycled back to the compressor arrangement for recompressing. Normally, axial compressors are not suitable to handle the typical pressure levels in a mixed refrigerant circuit with multiple cryogenic heat exchangers, due to the fixed optimal pressure ratios of the axial compressors.
The invention provides for a method of cooling a stream, wherein the stream is cooled in a heat exchanger against a refrigerant fluid being cycled in a refrigerant circuit, the cycling of the refrigerant fluid comprising:
(a) feeding a first refrigerant fluid into an axial compressor;
(b) compressing the first refrigerant fluid in the axial compressor, thereby obtaining a compressed first refrigerant fluid;
(c) feeding the compressed first refrigerant fluid at a first pressure level into a centrifugal compressor at a first inlet;
(d) feeding a second refrigerant fluid at a second pressure level into the centrifugal compressor at a second inlet, the second pressure level being lower than the first pressure level;
(e) compressing the compressed first refrigerant fluid fed in step (c) and the second refrigerant fluid fed in step (d) in the centrifugal compressor, thereby obtaining a compressed refrigerant fluid mixture;
(f) cooling the compressed refrigerant fluid mixture obtained in step (e) in a heat exchanger against a cooler stream, thereby obtaining a cooled compressed refrigerant fluid mixture;
(g) separating the cooled compressed refrigerant fluid mixture obtained in step (f) into at least two streams;
(h) evaporating the at least two streams obtained in step (g) at different pressure levels of a heat exchanger in heat exchanging contact with the stream to be cooled thereby cooling the stream; and
(i) retrieving the first and second refrigerant fluids from the at least two streams evaporated in step (h).
One or more embodiments of the invention are described in detail and by way of example only with reference to the accompanying drawings.
The present invention relates to a method and apparatus for cooling a stream, in particular a hydrocarbon stream such as natural gas.
In a further aspect the present invention relates to a compressor arrangement and in particular to the use thereof in a refrigerant circuit for use in a method and apparatus for producing a liquefied stream such as a liquefied hydrocarbon stream such as a liquefied natural gas (LNG) stream.
A problem of the use of known line-ups in the compressor arrangement is their inefficiency.
The present invention may minimize the above problem and may provide a more efficient method for producing a liquefied natural gas stream.
The present invention may provide an alternative compressor arrangement, in particular to be used in a refrigerant circuit using a mixed refrigerant with multiple cryogenic heat exchangers for cooling or liquefying a natural gas stream.
The present invention makes use of a surprisingly simple and flexible compressor arrangement containing a specific combination of an axial and a centrifugal compressor.
The invention provides for one or more of the following advantages.
An important advantage of the present invention is that—despite the presence of the axial compressor—a refrigerant fluid being composed of streams having different pressure levels and being cycled in a refrigerant circuit can be handled during compression in a surprisingly simple and efficient manner. This is in particular advantageous if a mixed refrigerant is used in the refrigerant circuit with multiple cryogenic heat exchangers.
A further advantage of the compressor arrangement used in the method according to the present invention, wherein an axial compressor is arranged partially parallel to a centrifugal compressor, is that a pressure ratio of about 6 across the axial compressor can be maintained while at the same time the compressor arrangement can handle various stream having different pressure levels.
Another advantage of the compressor arrangement used in the method according to the present invention is that a lower specific power is needed than if a single centrifugal compressor or two centrifugal compressors in series would be used.
An even further advantage of the present invention is that by use of the axial compressor the volumetric flow in any point of the centrifugal compressor in the compressor arrangement is significantly lowered.
As a method of cooling a stream such as a hydrocarbon stream, for example thereby producing an LNG stream is known as such, this is not fully discussed here in detail.
The person skilled in the art will understand that the stream to be cooled may have various compositions, but is preferably a hydrocarbon stream. The hydrocarbon stream may be any hydrocarbon-containing stream to be cooled, but is usually a natural gas stream obtained from natural gas or petroleum reservoirs. As an alternative the natural gas stream may also be obtained from another source, also including a synthetic source such as a Fischer-Tropsch process. Usually a natural gas stream is comprised substantially of methane. Preferably the natural gas comprises at least 60 mol % methane, more preferably at least 80 mol % methane. Depending on the source, the natural gas may contain varying amounts of hydrocarbons heavier than methane such 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 natural gas stream may have been pre-treated before cooling. This pre-treatment may comprise removal of undesired components such as H2O, 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 refrigerant fluid being cycled in the refrigerant circuit may be a single component refrigerant or a mixed refrigerant containing several compounds having different boiling points. For use in the production of LNG, the refrigerant fluid will usually be selected from one or more of the group consisting of nitrogen; lower hydrocarbons such as methane, ethane, ethylene, propane, propylene, butane, pentane; or mixtures thereof thereby forming a mixed refrigerant. Preferably a mixed refrigerant is used as the refrigerant fluid.
The first and second refrigerant fluids being fed in steps (a) and (d) are not limited to a specific composition. They may contain different components or different mixtures of components or they may be parts of the refrigerant stream having the same composition.
The heat exchanger in which the natural gas stream is cooled may be a single heat exchanger or a heat exchanger train comprising two or more heat exchangers or heat exchanging zones, as long as the at least two streams obtained in step (g) can be evaporated at different pressure levels.
The separation of the cooled compressed refrigerant fluid mixture in step (g) may be performed in various ways, also depending on whether a single component refrigerant or a mixed refrigerant is used as the refrigerant fluid being cycled in the refrigerant circuit. If a mixed refrigerant is used, e.g. a T-junction may be used. If a single component is used, the separation may take place while the cooled compressed refrigerant fluid mixture obtained in step (f) passes through the heat exchanger or a zone thereof intended for cooling the natural gas stream in step (h). In the latter case, a part of the single component evaporates at a higher pressure level, while the remainder is passed to a lower pressure zone of the same or other heat exchanger and is evaporated there.
In a further aspect, the present invention provides an apparatus for cooling a stream, in particular a hydrocarbon stream such as natural gas, optionally producing a liquefied natural gas stream, wherein the stream is cooled in a heat exchanger against a refrigerant fluid being cycled in a refrigerant circuit, the refrigerant circuit at least comprising:
Preferably, the separator comprises a T-junction, in particular if a mixed refrigerant is the refrigerant fluid being cycled in the refrigerant circuit.
In an even further aspect the present invention provides a refrigerant circuit as described in the apparatus according to the present invention and the use thereof for cooling a stream, in particular natural gas.
In an other aspect the present invention provides a compressor arrangement as described in the apparatus according to the present invention, the compressor arrangement comprising:
The refrigerant circuit and compressor arrangement according to the present invention are not only suitable (and preferably intended) for cooling a natural gas stream, but may be used for any fluid to be cooled.
The invention will now be described by way of example in more detail with reference to the accompanying non-limiting drawings, wherein:
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.
Reference is made to
Although according to the embodiment of
The apparatus 1 comprises a heat exchanger train 2 comprising two or more heat exchangers (or heat exchanging zones) 2a and 2b, in which the natural gas stream 10 is cooled against a refrigerant being cycled in a refrigerant circuit 3. After cooling in the heat exchanger train 2, a cooled natural gas stream (which may be partly liquefied) 100 is obtained.
The person skilled in the art will readily understand that the apparatus may comprise more heat exchangers thereby cooling the natural gas stream 10 in several steps into liquefaction. As an example, the apparatus 1 may comprise a pre-cooling system with a pre-cooling refrigerant circuit, a main cryogenic system with a main refrigerant circuit and a sub-cooling system with a sub-cooling refrigerant circuit. However, for reasons of simplicity, only one cooling system with one refrigerant cycle has been shown in
Further, the person skilled in the art will understand that the natural gas stream 10 may have been pre-treated, e.g. to remove any undesired components such as H2O, CO2, sulphur compounds such as H2S, and the like.
The refrigerant circuit 3 comprises a specific compressor arrangement 4 being composed of an axial compressor 5 and a centrifugal compressor 6. If desired, the compressor arrangement 4 may comprise more than two compressors.
The axial compressor 5 has an inlet 7 for a first refrigerant fluid 20 to be compressed and an outlet 8 for a compressed first refrigerant fluid 30.
The centrifugal compressor 6 has a first inlet 9 for the compressed first refrigerant fluid 30 that has been compressed in the axial compressor 5 and a second inlet 11 for a second refrigerant fluid 40. If desired, stream 30 leaving the outlet 8 of the axial compressor 5 may be intermediately cooled against another stream (not shown) before passing to the inlet 9 of centrifugal compressor 6.
The compressed first refrigerant fluid 30 and the second refrigerant fluid 40 are concurrently compressed in the centrifugal compressor 5 thereby obtaining a compressed refrigerant fluid mixture 50 being removed from outlet 12.
Further the refrigerant circuit 3 comprises a heat exchanger 13 for cooling the compressed refrigerant fluid mixture 50 (which is fed via inlet 18) against a cooler stream, thereby obtaining a cooled compressed refrigerant fluid mixture 60 (which is removed via outlet 19). As an example, the heat exchanger 13 may be an air or water cooler, wherein air or water functions as the coolant.
The outlet 19 of the heat exchanger 13, in which the compressed refrigerant fluid mixture 50 has been cooled, is connected via line 60 to the first inlet 21a of the cold side 17a of the natural gas cooling heat exchanger 2a.
Furthermore, the apparatus 1 comprises a separator 33 for separating the cooled compressed refrigerant fluid mixture 65 into at least two streams. In the embodiment of
The two streams 70, 80 obtained as described above are evaporated at different locations and at different pressure levels in the heat exchanger train 2 thereby cooling the natural gas stream 10. In the embodiments shown in
The natural gas cooling heat exchangers 2a, 2b have a hot side schematically shown in the form of tubes 14a, 14b having inlets 15a, 15b for natural gas 10 and outlets 16a, 16b for cooled natural gas. The tubes 14a, 14b are arranged in the cold side 17a, 17b, which can be a shell side of the natural gas cooling heat exchangers 2a, 2b. The outlet 16a of heat exchanger 2a is connected via line 75 to inlet 15b of heat exchanger 2b.
In the embodiment of
The stream 65 removed from the first outlets 31a is split in separator 33 into the streams 70 and 80. Stream 80 is passed to the first inlet 21b of the heat exchanger 2b, whilst stream 70 is expanded in expander 45a and returned (as stream 90) via second inlet 27a into the heat exchanger 2a in which it is evaporated. The evaporated stream is collected at second outlet 22a at the bottom of the heat exchanger 22a.
The stream 80 is fed at first inlet 21b into heat exchanger 2b, passed through the heat exchanger as stream 110b and removed from the heat exchanger 2b at the first outlet 31b as stream 85. Subsequently, stream 85 is expanded in expander 45b and returned via line 95 at second inlet 27b into the heat exchanger 2b in which it is evaporated. The evaporated stream is collected at second outlet 22b near the bottom of the heat exchanger 2b.
If a further heat exchanger 2c is present, then the stream 85 removed from outlet 31b of heat exchanger 2b may be further split in a suitable manner. One of the streams obtained then would be used as a feed to the expander 45b, whilst (one of) the other stream(s) could be used as a feed for the heat exchanger 2c.
The second outlet 22 of the cold side 17a is connected by means of return conduit 40 to the second inlet 11 of the centrifugal compressor 6. The second outlet 22b of the cold side 17b is connected by means of return conduit 20 to the inlet 7 of axial compressor 5. Usually, knock out drums (not shown) are present in the lines 20, 40 to prevent that liquid is fed into the compressors 5, 6.
During normal operation, natural gas 10 is supplied to the cooling heat exchanger train 2, is stepwise cooled in heat exchangers 2a, 2b against the refrigerant being cycled in the circuit 3 as described above, and is removed as a cooled fluid 100 from the heat exchanger 2b at outlet 16b.
Generally, the second refrigerant fluid 40 has a higher pressure than the first refrigerant fluid 20. Preferably, the first refrigerant fluid 20 is fed into the axial compressor 5 at a pressure in the range of 2-5 bar, preferably about 3 bar. Also it is preferred that the compressed first refrigerant fluid 30 is fed into the centrifugal compressor 6 at a pressure in the range of 12-30 bar. It is even more preferred that the pressure of the compressed first refrigerant fluid 30 that is fed into the centrifugal compressor 6 is five to seven times as high as the pressure of the first refrigerant fluid 20 that is fed into the axial compressor 5, preferably about 6 times as high. Also it is preferred that the second refrigerant fluid 40 is fed into the centrifugal compressor 6 at a pressure in the range of 6-15 bar and that the compressed refrigerant fluid mixture 50 has a pressure in the range of 25-60 bar. Furthermore the compressed first refrigerant fluid 30 is at a higher pressure than the second refrigerant fluid 40.
If the refrigerant circuit 3 is used for pre-cooling or liquefaction purposes, the temperature at the first inlet 21a of heat exchanger 2a will generally be in the range of from 50 to −50° C.; the temperature at the first outlet 31a of heat exchanger 2a will be in the range of from 20 to −80° C. Further, the temperature at the first inlet 21b of heat exchanger 2b will generally be in the range of from 20 to −80° C.; the temperature at the first outlet 31b of heat exchanger 2b will be in the range of from 0 to −110° C.
The following Example is used to further illustrate the present invention.
In a calculated simulation, the process scheme of
Otherwise than the process scheme indicated in
For the simulation the specifications of axial compressor K1430 and of centrifugal compressor K1440 were used.
Table 1 shows the temperature, pressure, flow rate and phase condition of the various natural gas streams in a simulated example, whilst Table 2 shows the same for the various streams within the refrigerant cycle. In the simulated example, stream 60 comprises 1.8 mol % methane, 50.8 mol % ethane and 47.4 mol % propane.
From further calculations it followed that the pre-cool cycle as used in the Example resulted in an efficient pre-cooling cycle. As can be seen from Table 3 an increase (268.1/271.3×100%=0.99%) of combined power would result if the compressor arrangement 4 according to the present invention is replaced by two centrifugal compressors in series. As a result of the increased power, also a decrease in Coefficient of performance (CoP—defined as the ratio between the heat transferred from the natural gas and other fluids to be cooled (180.5 MW in the Example) and the power invested in the cycle (respectively 87.6 and 90.8 MW)) would result: 2.06 vs. 1.99.
The person skilled in the art will readily understand that the present invention can be modified in many various ways without departing from the scope of the appended claims. As an example, stream 50 may be heat exchanged against another stream.
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