Patent Grant
7152429
1. Field of the Invention
The present invention relates generally and according to a first aspect to methods of separating a dry feed gas mainly comprising methane, ethane and propane, typically natural gas, and in a second aspect to industrial installations and equipment allowing these methods to be carried out.
2. Description of the Art
More precisely, the invention relates, according to a first aspect, to a method of separating a dry feed gas, mainly comprising methane, ethane, and propane, into a first, relatively more volatile product, called treated gas, and a second, relatively less volatile product, called C2 plus fraction, comprising:
According to a second aspect, the invention relates to an installation for separating a dry feed gas, mainly comprising methane, ethane and propane, into a first, relatively more volatile product, called treated gas, and a second, relatively less volatile product, called C2 plus fraction, comprising:
This method and the installation which carries it out are known from the prior art, in particular from U.S. Pat. No. 4,157,904. This patent discloses several methods and their corresponding installations having the characteristics described above, these methods also providing for mixing part of the first bottom stream with the secondary stream prior to cooling, expansion and feeding into the distillation device.
The distillation device used by these methods is formed by a distillation column. The secondary stream is introduced at the top of the column and acts as a reflux and the main flux is introduced at an intermediary stage. The cooled first bottom stream is introduced at a lower stage to the main stream.
The top of the column, between the introduction stage of the main stream and the introduction stage of the secondary stream, acts as an extraction zone for C2 and higher hydrocarbons from the main stream, and the bottom of the column, below the main stream introduction stage, acts as a methane-removal zone.
The ethane and propane extraction efficiencies can be increased by lowering the temperature profile of the column. This requires a lot of energy if the power of the cooling cycle used to cool the feed gas is simply increased.
Another way of lowering this profile is to expand the streams feeding the distillation column to a larger extent, whereby these streams are cooled but the operating pressure of the column is also reduced. The power required for recompressing the first product will therefore increase.
U.S. Pat. No. 4,157,904 proposes plans allowing this profile to be lowered by optimising energy efficiency, mainly by mixing part of the first bottom stream with the secondary stream prior to cooling, expansion and feeding into the distillation device, which, as a result of the physico-chemical properties of these streams, allows lower temperatures for feeding the distillation column to be reached without having an adverse effect on the operating pressure.
By contrast, the reflux, formed by the mixture of part of the first bottom stream and the secondary stream, is richer in C2 and higher hydrocarbons than the secondary stream alone, which has an adverse effect on the extraction of C2 and higher hydrocarbons from the main stream in the top zone of the column.
In this context, it is the aim of the present invention to optimise both the ethane and propane extraction efficiency and the energy efficiency of the method and corresponding installation.
To this effect, the invention, according to a first aspect, furthermore in accordance with the generic definition given above, is essentially characterised in that the distillation device of the separation method comprises at least first and second distillation columns operating at different pressures.
In one possible embodiment of the method according to the invention, the first and second distillation columns operate at pressures P1 and P2 respectively, the difference between P1 and P2 being between 5 and 25 bar.
According to one of the advantageous aspects of the method according to the invention, operating pressure P1 of the first distillation column can be between 30 and 45 bar.
According to one the advantageous aspects of the method according to the invention, operating pressure P2 of the second distillation column can be between 15 and 30 bar.
According to one the advantageous aspects according to the invention, the second distillation column can produce a fourth top stream and a fourth bottom stream, the fourth bottom stream forming the second bottom stream produced by the distillation device, at least part of the fourth top stream feeding, after compression and at least partial liquefaction, a top stage of the first distillation column.
According to one of the advantageous aspects of the method according to the invention, the first distillation column can produce a third top stream and a third bottom stream, the third top stream forming the second top stream produced by the distillation device, the first distillation column being fed at a lower stage by at least part of the expanded main stream and at an intermediary stage by at least part of the expanded secondary stream.
According to one of the advantageous aspects of the method according to the invention, the second distillation column can be fed at an upper stage by at least part of the third bottom stream produced by the first distillation column, and at an intermediary stage by at least part of the first cooled bottom stream.
According to one the advantageous aspects of the method according to the invention, the second distillation column can comprise at least a reboiler.
According to one the advantageous aspects of the method according to the invention, the fourth top stream can release part of its cooling potential in the exchanger prior to compression.
According to one of the advantageous aspects of the method according to the invention, the fourth top stream after compression can undergo a plurality of cooling stages, with at least one in the exchanger, then expansion before feeding the first distillation column.
The invention, according to a second aspect, furthermore in accordance with the generic definition given above, is essentially characterised in that the distillation device of the separation installation comprises at least first and second distillation columns operating at different pressures.
In one possible embodiment of the installation according to the invention, the first and second distillation columns operate at pressures P1 and P2 respectively, the difference between P1 and P2 being between 5 bar and 25 bar.
According to one of the advantageous aspects of the installation according to the invention, operating pressure P1 of the first distillation column can be between 30 and 45 bar.
According to one of the advantageous aspects of the installation according to the invention, operating pressure P2 of the second distillation column can be between 15 and 30 bar.
According to one of the advantageous aspects of the installation according to the invention, the second distillation column can produce a fourth top stream and a fourth bottom stream, the fourth bottom stream forming the second bottom stream produced by the distillation device, at least part of the fourth top stream feeding, after compression and at least partial liquefaction, a top stage of the first distillation column.
According to one of the advantageous aspects of the installation according to the invention, the first distillation column can produce a third top stream and a third bottom stream, the third top stream forming the second top stream produced by the distillation device, the first distillation column being fed at a lower stage by at least part of the expanded main stream and at an intermediary stage by at least part of the expanded secondary stream.
According to one of the advantageous aspects of the installation according to the invention, the second distillation column can be fed at an upper stage by at least part of the third bottom stream produced by the first distillation column, and at an intermediary stage by at least part of the first cooled bottom stream.
According to one of the advantageous aspects of the installation according to the invention, the second distillation column can comprise at least a reboiler.
According to one of the advantageous aspects of the installation according to the invention, the fourth top stream can release part of its cooling potential in the exchanger prior to compression.
According to one of the advantageous aspects of the installation according to the invention, the fourth top stream after compression can undergo a plurality of cooling stages, with at least one in the exchanger, then expansion, prior to feeding the first distillation column.
Other characteristics and advantages of the invention will emerge clearly from the following description by way of informative and non-limiting example with reference to the appended figures, in which:
A conventional separation method according to the prior art will first be described with reference to
The flow rate values, temperature values, pressure values and composition values given in the description below are values obtained by numerical simulation of the method in an embodiment shown in
This method is fed by a feed gas stream 1, typically natural gas, mainly containing methane, ethane and propane. This gas arrives in a dry form and typically has the following characteristics: pressure 73 absolute bar, temperature 40° C., flow rate 30000 kgmol/h.
The approximate molar flow rates in kgmol/h of the main components of the feed gas are given in the table below.
The method produces two products: a first product 17, called treated gas, formed mainly by methane and depleted in C2 and higher hydrocarbons in comparison to feed gas 1, notably ethane and propane, and a second product 34, called C2 plus fraction, mainly formed by ethane and propane and containing most of the C2 and higher hydrocarbons provided by feed gas 1.
Feed gas 1 undergoes a first cooling operation to a temperature of minus 50° C. in a cryogenic exchanger E1 in order to produce a cooled gas stream 2. A fraction of the gas is condensed during this operation, approximately 10%, the less volatile components being condensed to a greater extent than the more volatile components.
This cooled gas 2 then undergoes a second separation and treatment operation. Cooled gas stream 2 is separated in a separator reservoir B1 into a first top stream 3 relatively depleted in C2 and higher hydrocarbons and a first bottom stream 4 relatively enriched in C2 and higher hydrocarbons.
First top stream 3 is essentially gaseous, and the first bottom stream is essentially liquid and their flow rates are approximately 27000 and 3000 kgmol/h respectively.
First bottom stream 4 then undergoes expansion to a pressure of 25 absolute bar, which causes cooling to minus 80° C. and partial vapourisation of approximately 45% of the liquid in order to form a first cooled bottom stream 10.
First top stream 3 is divided into a main stream 5 and a secondary stream 6 with flow rates of 20000 kgmol/h and 7000 kgmol/h respectively. Main stream 5 is expanded to a pressure of 25 absolute bar in a turbine T1 coupled to a compressor K1 in order to form an expanded main stream 7. This expansion is accompanied by cooling to minus 92° C. and partial condensation of approximately 20% of the gas.
Secondary stream 6 is cooled and liquefied in a second cryogenic exchanger E2 to minus 99° C. in order to form a stream 8, this resulting stream 8 then being expanded to 25 absolute bar, turning it into an expanded secondary stream 9. This expansion is accompanied by cooling to minus 103° C. and partial vapourisation of approximately 6% of the liquid.
The various streams produced by the separation and treatment operation then undergo distillation in a distillation device C3, typically a distillation column in the prior art.
Expanded main stream 7 feeds distillation device C3 at an intermediary stage, expanded secondary stream 9 feeding distillation device C3 at a top stage and forming a reflux.
First cooled bottom stream 10 feeds distillation device C3 at an intermediary stage situated under the feed stage of expanded main stream 7.
Distillation device C3 operates under 25 absolute bar and is typically equipped with two reboilers formed by zones of cryogenic exchanger E1 in the embodiment illustrated in
The first reboiler is fed by a stream 18 with a flow rate of approximately 7000 kgmol/h and a temperature of minus 56° C., drawn off at a stage S1 situated under the feed stage of first cooled bottom stream 10, the reheated stream forming a stream 19 with a temperature of minus 19° C. which feeds a stage S2 situated at a lower level than stage S1.
The second reboiler is fed with a stream 20 with a flow rate of 4000 kgmol/h and a temperature of 5° C., drawn off at a stage S3 situated at a lower level than stage S2, the reheated stream forming a stream 21 with a temperature of 14° C. which feeds a stage S4 situated at lower level than stage S3.
Distillation device C3 produces a second, essentially gaseous, top stream 11 and a second, essentially liquid, bottom stream 22 with flow rates of 27200 kgmol/h and 2800 kgmol/h respectively.
Second top stream 11 is relatively depleted in C2 and higher hydrocarbons, and second bottom stream 22 is relatively enriched in C2 and higher hydrocarbons.
Second bottom stream 22, with a temperature of 14° C. and a pressure of 25 absolute bar, after compression to 35 absolute bar by a pump P1 turning it into a stream 33 and reheating to 32° C. in exchanger E1, forms second product 34.
The subsequent operations for treating second current 34, which are not covered by the present invention and, therefore, are not described, establishes a molar ratio between C1 hydrocarbons and C2 hydrocarbons of approximately 0.01 in this second current 34.
Second top stream 11 releases part of its calorific potential to secondary stream 6 in cryogenic exchanger E2 in order to form a stream 12 with a temperature of minus 73° C., then undergoes a second reheating stage to 33° C. in cryogenic exchanger E1 in order to form a stream 13.
This stream 13 is compressed to 30 absolute bar in compressor K1 coupled to turbine T1, turning it into a stream 14, and cooled to 40° C. by exchanger E3, turning it into a stream 15.
This stream 15 undergoes a second compression to 75 absolute bar by a compressor K2, turning it into a stream 16, whereby said compressor can, for example, be coupled to a gas turbine GT, then cooled to 45° C. by exchanger E4 and forms first product 17.
In accordance with the operating conditions, a cooling cycle provides cryogenic exchanger E1 with the additional cooling power necessary to cool feed gas 1.
This cycle is not useful in the operating conditions described above, but the description thereof is nevertheless given below.
A stream 51 of gaseous propane is compressed to 14 absolute bar by a compressor K4, typically equipped with an electric motor, in order to produce a stream 52, then cooled to 40° C. by an exchanger E5, turning it into a liquid stream 53.
Stream 53 is cooled to minus 20° C. in cryogenic exchanger E1 in order to form stream 54 which is then expanded to 4 absolute bar, turning it into a stream 55.
Stream 55 is vapourised in cryogenic exchanger E1 to form stream 51 with a temperature of minus 6° C.
The flow rates for components of the main streams of the method are indicated in the table below in kgmol/h:
The method according to the invention will now be described with reference to
The method is fed with a feed gas stream 1 having the same properties as that described above.
The operations for cooling feed gas 1 and separating and treating cooled gas 2 are identical to those of the prior art. Only the operational conditions change, as will be described below.
First bottom stream 4 is expanded to 20 absolute bar, whereby the temperature of first cooled bottom stream 10 is brought to minus 86° C.
The flow rates of main stream 5 and secondary stream 6 are 26000 kgmol/h and 1000 kgmol/h respectively. Main stream 5 is expanded to 38.5 absolute bar, whereby the temperature of expanded main stream 7 is brought to minus 77° C.
Secondary stream 6 is cooled in cryogenic exchanger E2 to minus 91° C. and expanded to 38.5 absolute bar, whereby the temperature of expanded secondary stream 9 is brought to minus 92° C.
Distillation device C3 comprises first and second distillation columns C1 and C2 operating under pressures P1 and P2 of 38.5 and 20 absolute bar respectively.
First distillation column C1 produces a third top stream 11 and a third bottom stream 23 with flow rates of 27300 and 8000 kgmol/h respectively, and second distillation column C2 produces a fourth top stream 25 and a fourth bottom stream 22 with flow rates of 8310 and 2730 kgmol/h respectively.
Second distillation column C2 is fed with first cooled bottom stream 10 at an intermediary stage and with a third expanded bottom stream 24 at an upper stage. Third expanded bottom stream 24 is produced by expanding to 20 absolute bar and minus 98° C. third bottom stream 23 which exits first distillation column C1 at 38.5 absolute bar and minus 78° C.
Fourth bottom stream 22 exits at 20 absolute bar and 5° C.
Fourth top stream 25, with a temperature of minus 97° C. and a pressure of 20 absolute bar, releases part of its cooling potential in cryogenic exchanger E2 in order to form stream 26 at minus 60° C.
This stream 26 is then reheated in cryogenic exchanger E1 to 38° C., turning it into a stream 27 which is then compressed to 50 bar and 128° C. by a compressor K3 in order to form a stream 28. Compressor K3 is typically equipped with an electric motor.
Stream 28 is then cooled to 40° C. by an exchanger E6 in order to produce a stream 29, undergoes a second cooling stage to minus 50° C. in cryogenic exchanger E1, turning it into a stream 30, this stream 30 undergoing a third cooling stage to minus 91° C. in cryogenic exchanger E2, turning it into a stream 31.
Stream 31, after expansion to 38.5 absolute bar and minus 92° C., forms a stream 32 which feeds a top stage of first distillation column C1.
First distillation stage C1 is also fed with expanded main stream 7 at a lower level, and with expanded secondary stream 9 at an intermediary level.
Third top stream 11 exits first distillation column C1 at minus 89° C. and 38.5 absolute bar and undergoes treatment identical to the treatment described for the prior art.
Stream 11 is reheated to minus 69° C. in order to form stream 12, stream 12 being reheated to 38° C. in order to form stream 13.
This stream 13 undergoes two successive compressions by compressors K1 and K2 to 44 absolute bar and 51° C. then 75 absolute bar and 96° C., each compression being followed by cooling to 40° C. and 45° C. respectively.
Fourth bottom stream 22 is compressed and reheated to 35° C. and 35 bar.
It will be noted that first and second products 17 and 34 are produced under the same temperature and pressure conditions as for the method according to the prior art, thereby allowing a comparison of the energy results.
Second distillation column C2 is equipped with two reboilers formed by zones of cryogenic exchanger E1 in the embodiment illustrated in
The first reboiler is fed by stream 18 with a flow rate of approximately 5700 kgmol/h and a temperature of minus 55° C., drawn off at a stage S1 situated below the feed stage of first cooled bottom stream 10, the reheated stream forming stream 19 with a temperature of minus 20° C. which feeds a stage S2 situated at a lower level than stage S1.
The second reboiler is fed with stream 20 with a flow rate of 3600 kgmol/h and a temperature of minus 3° C., drawn off at a stage S3 situated at a lower level than stage S2, the reheated stream forming stream 21 with a temperature of 5° C. which feeds a stage S4 situated at a lower level than stage S3.
The flow rates for components of the main streams of the method are given in the table below in kgmol/h:
Another example of operation of the method according to the invention will be described below, operating pressure P1 of first distillation column C1 still being 38.5 absolute bar and operating pressure P2 of second distillation column C2 being 25 absolute bar.
The properties of the main streams are grouped together in the table below.
In this example of operation, the related cooling cycle is used, the propane flow rate being approximately 550 kgmol/h in the loop.
The comparison of the main properties of the method according to the prior art and of the two cases of operation of the method according to the invention shows that, for similar levels of ethane and propane extraction, the method according to the invention allows a considerable saving in power and, therefore, savings in cost.
The saving in power achieved with the method according to the invention is approximately 5000 kW in contrast to the prior art for the considered flow rates.
Other variations are included in the present invention.
Operating pressure P1 of distillation column C1 can vary from 30 to 45 bar and operating pressure P2 of distillation column C2 can vary from 15 to 30 bar. The energy efficiency is better when the difference between P1 and P2 is between 5 and 25 bar.
The fact that a first distillation column C1 is used at a higher pressure P1 allows savings to be made for the final compression of first product 17 with these savings largely counterbalancing the cost of the intermediary compression of fourth top stream 25.
Furthermore, the method benefits in terms of its separating performance from the fact that fourth top stream 25, used as a reflux in first distillation column C1, is extremely depleted in C2 and higher hydrocarbons, as shown in the following table:
| Number | Date | Country | Kind |
|---|---|---|---|
| 01 14141 | Oct 2001 | FR | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/FR02/03490 | 10/11/2002 | WO | 00 | 4/30/2004 |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
| WO03/038358 | 5/8/2003 | WO | A |
| Number | Name | Date | Kind |
|---|---|---|---|
| 4702819 | Hill et al. | Oct 1987 | A |
| 5953935 | Sorensen | Sep 1999 | A |
| 6182469 | Hudson et al. | Feb 2001 | B1 |
| 6244070 | Chen et al. | Jun 2001 | B1 |
| Number | Date | Country |
|---|---|---|
| 2 578 637 | Sep 1986 | FR |
| Number | Date | Country | |
|---|---|---|---|
| 20050000245 A1 | Jan 2005 | US |
