Patent Application
20120067080
The present invention is directed to a refrigerant compression circuit for use in the liquefaction of natural gas or other methane-rich gas streams. The invention is more specifically directed to a mixed component refrigerant compression circuit.
The cryogenic liquefaction of natural gas is routinely practiced as a means of converting natural gas into a more convenient form for transportation and storage. Liquefaction of large volumes of gas using a refrigerant circuit is energy and capital intensive. Broadly speaking, a plant for liquefying natural gas comprises a main heat exchanger in which a hydrocarbon gas feed stream is liquefied by means of indirect heat exchange with evaporating refrigerant in one or more stages. The plant further comprises a refrigerant circuit in which evaporated refrigerant(s) are compressed, cooled and returned to the main heat exchanger. The refrigerant circuit typically includes a compressor train consisting of at least one compressor body driven by means of a mechanical driver (e.g., a gas turbine, a steam turbine, or an electric motor) that is connected to the shaft of the compressor body via a common shaft or via a gearbox. The configuration of compressors and mechanical drivers in a gas processing plant greatly influences the energy efficiency of the plant.
New gas liquefaction and other gas processing plants are being designed for ever-increasing production rates in order to realize the favourable economic benefits associated with larger plants. These larger plants have larger refrigeration duties with higher refrigerant circulation rates, and therefore larger refrigerant compressors are required. The amount of natural gas which can be cooled per unit of time in the refrigerator is proportional to the volumetric flow rate of the refrigerant through the refrigerator. However, there is a practical upper limit to the volumetric flow rate which can be handled by a single large compressor with the result that the maximum achievable production rate is being limited by the maximum available compressor sizes.
At the present time, the largest available single compressor bodies suitable for mixed refrigerant service are limited to suction volumetric flows of about 250,000 m3/hr. This limit has contributed to LNG train capacities remaining below 5.5 million tonnes per annum. In order to overcome this limitation, several approaches have been employed or proposed. One approach has been to increase the number of separate refrigerant cycles from two to three. Another approach is to duplicate the entire mixed refrigerant compression system using two complete parallel compression strings, with each string being arranged on a separate shaft using its own driver system. Using this approach, the entire mixed refrigerant compression flow is shared between the two parallel compression strings in order to overcome the limitation imposed by the maximum volumetric flow rate which can be handled by a single compressor body. The parallel string concept can be done in two different ways. One way is to duplicate the compressors only, then mix the flow through the other equipment and split the flow before it passes through the compressors. The other way is to have two unconnected (but identical) mixed refrigerant circuits, having two cooling systems and two main exchangers as well as two compressors. The use of parallel strings may be preferred to a system with a third separate refrigerant cycle, since if one of the parallel strings is shut down, the refrigeration cycle can continue to operate at a reduced capacity using the remaining string, thus maximising the availability of the plant in the event of a compressor outage. However, the duplication inherent in the use of parallel strings may increase the capital cost of a gas processing plant.
Other prior art refrigerant compression circuits are described in International patent publication number WO 01/44734; U.S. Pat. No. 3,527,059; U.S. Pat. No. 6,691,531; U.S. Pat. No. 6,637,238; U.S. Pat. No. 6,691,531; and, U.S. Pat. No. 6,962,060.
There exists a continuing need in the gas processing field to provide alternative plants and methods to eliminate the limitations on the size and volumetric flow of single large compressors without the use of parallel strings for all stages of compression. The present invention overcomes or ameliorates at least one of the aforementioned drawbacks of the prior art to provide an alternative method for the design of a refrigerant compression circuit for a hydrocarbon liquefaction plants.
According to one aspect of the present invention there is provided a refrigerant circuit for use in a liquefaction plant, the refrigerant circuit comprising:
To remove the heat of compression from the refrigerant, the refrigerant circuit may further comprise a first intercooling heat exchanger, wherein the first intercooling heat exchanger is arranged between the first compression stage and the second compression stage. In one form, the first merging means is arranged upstream of the first intercooling heat exchanger.
In one form, the first distribution means is arranged to split the mass flow of refrigerant gas evenly between the at least two parallel compressor bodies. The size of the at least two parallel compressor bodies will depend, in part, on the flow rate of refrigerant being processed by the refrigerant circuit and the size of each compressor body. In one form, each of the at least two parallel compressor bodies is capable of compressing a suction volumetric flow rate of refrigerant gas of at least 100,000 m3/h or at least 150,000 m3/h or at least 200,000 m3/h.
In one form, one or both of the first and second compression stages comprise at least two segments arranged in a single back to back compressor body.
Advantageously, in one form, the refrigerant circuit comprises a first compression string drivingly coupled to a first driver and a second compression string drivingly coupled to a second driver, and the first and second compression stages are arranged on the first and second compression string such that each of the first and second compression strings comprises no more than two compressor bodies.
In one form, the first and second drivers provide substantially even power draw to the refrigeration circuit.
Alternatively or additionally, at least one of the first and second drivers may be a gas turbine and the refrigeration circuit may further comprise a third driver in the form of a steam turbine driven by the waste heat recovered from the exhaust gas of the gas turbine.
In one form, the refrigeration circuit further comprises a third compression stage for compressing the mixed refrigerant gas from the third pressure to a fourth pressure. To remove the heat of compression from the refrigerant, the circuit may further comprise a second intercooling heat exchanger arranged between the second compression stage and the third compression stage for removing heat of compression from the refrigerant.
In one form, the second and third compression stages are combined within a single back to back compressor body.
In one form, the circuit further comprises a second distribution means for splitting the mass flow of refrigerant gas to the second stage of compression across the at least two parallel first and second compressor bodies, such that a first stream of refrigerant gas is fed to the suction inlet of the first compressor body and a second stream of refrigerant gas is fed to the suction inlet of the second compressor body, and a second merging means for recombining the first stream of refrigerant gas with the second stream of refrigerant gas downstream of the second compression stage for delivery to the third compression stage.
According to a second aspect of the present invention there is provided a plant for the production of a liquefied hydrocarbon product such as liquefied natural gas, the plant comprising:
In one form of the plant, the first distribution means is arranged upstream of the main heat exchanger system.
According to a third aspect of the present invention there is provided a method for cooling, preferably liquefying, a hydrocarbon stream, wherein the hydrocarbon stream is cooled by indirect heat exchange with an evaporating refrigerant, and the evaporated refrigerant is cooled using a refrigerant circuit according to the first aspect of the present invention.
According to a fourth aspect of the present invention there is provided a refrigerant circuit substantially as herein described with reference to and as illustrated in the accompanying drawings.
In order to facilitate a more detailed understanding of the nature of the invention embodiments will now be described in detail, by way of example only, with reference to the accompanying drawings, in which:
The present invention will now be described in greater detail with reference to the accompanying drawings wherein several preferred embodiments of the present invention are set forth. Those skilled in the art will recognized that the accompanying drawings are schematic representations only and therefore, many items of equipment that would be needed in a commercial plant for successful operation have been omitted for the sake of clarity. Such items might include, for example, compressor controls, flow, level, temperature and pressure controls, pumps, motors, filters, additional heat exchangers, and valves, etc. It will be readily appreciated that a person skilled in the art would be able to include such items in accordance with standard engineering practice.
The term “compressor” as used herein refers to a device used to increase the pressure of an incoming fluid by decreasing its volume.
The term “compressor body” as used herein refers to a casing which holds the pressure side of the fluid passing through a compressor. While the compressors bodies used for the LPMR stage may be centrifugal (radial) type or axial, it is preferable to use centrifugal (radial) compressor bodies for the MPMR and HPMR compression stages.
The term “compression string” is used to describe one or more compressor bodies mounted on a common shaft and driven by a common driver.
The term “driver” as used herein refers to a mechanical device such as a gas turbine, a steam turbine, an electric motor or a combination thereof which is used to cause rotation of a shaft upon which a compression string is mounted.
The term “stage” as used herein means a compressor or compressor segment having one or more impellers wherein the mass flow of the fluid being compressed in the stage is constant through the stage. For mixed refrigerant compression, each stage is optionally defined by intercooling between them.
The term “intercooling” is used to refer to a process by which heat of compression is removed from a fluid between stages.
The term “back-to-back compressor” refers to a compressor body having two compression sections within a single casing, each stage having one inlet and one outlet.
As used herein, the terms “upstream” and “downstream” shall be used to describe the relative positions of various components of a natural gas liquefaction plant along the flow path of natural gas through the plant.
Preferred embodiments of the present invention are ideally suited to LNG trains with a capacity in the range of 5.5-6.5 million tonnes per annum (“mtpa”), but can be modified to suit processing plants of other capacities.
Numerous systems exist in the prior art for the liquefaction of a hydrocarbon feed stream by heat exchange with one or more refrigerants such as propane, propylene, ethane, ethylene, methane, nitrogen or combinations of the preceding refrigerants (so-called “mixed refrigerant” systems). For example, U.S. Pat. No. 4,698,080 discloses a liquefaction plant of the so-called cascade type having three refrigeration circuits operating with different refrigerants, propane, ethylene and methane. An alternative to the cascade-type liquefaction plant is a so-called propane-pre-cooled multi-component or “mixed refrigerant” (MR) liquefaction plant. Examples of liquefaction processes using mixed refrigerants are given in U.S. Pat. No. 5,832,745, U.S. Pat. No. 6,389,844, U.S. Pat. No. 6,370,910 and U.S. Pat. No. 7,219,512 (the contents of which are hereby specifically incorporated by reference). As methods and systems for liquefying a hydrocarbon stream are well known in the art they do not form a portion of the present invention and thus the operating conditions of the refrigeration side and the compositions of the refrigerants are not discussed in detail here.
The hydrocarbon stream to be liquefied may be any suitable hydrocarbon-containing stream, such as a natural gas stream obtained from natural gas or petroleum reservoirs or natural gas from a synthetic source such as a Fischer-Tropsch process. Whilst the composition of this gas stream may vary significantly, the hydrocarbon stream is comprised substantially of methane (e.g. >60 mol % methane). Depending on the source, the hydrocarbon stream may contain varying amounts of hydrocarbons heavier than methane such as ethane, propane, butane and pentane as well as some aromatic hydrocarbons. The hydrocarbon stream may also contain undesirable non-hydrocarbon components such as H2O, mercury, CO2, H2S, mercaptans, and other sulphur compounds. Various pre-treatment steps provide a means for removing undesirable components from the natural gas feed stream prior to liquefaction. As these pre-treatment steps are well known to the person skilled in the art, they do not form a portion of the present invention and are not further discussed here.
During normal operation a pre-treated hydrocarbon feed stream is pre-cooled using one or more pre-cooling heat exchangers before being supplied to a main cryogenic heat exchanger system (MHE) comprising one or more main heat exchangers. In the main heat exchanger system, the pre-cooled hydrocarbon feed stream is subjected to further cooling, and liquefied by means of indirect heat exchange with a refrigerant, in this example, an evaporating mixed refrigerant. When the hydrocarbon feed stream is natural gas, liquefied natural gas is removed from the discharge end of the main heat exchanger system. Specific examples of an indirect heat exchanger for use as one of the main heat exchangers include a spiral wound heat exchanger, a shell-and-tube heat exchanger, and a brazed aluminium plate-fin heat exchanger. Evaporated mixed refrigerant is removed as a gas from the main heat exchanger system and is passed to a refrigerant compressor circuit for compressing the evaporated refrigerant gas so that it can be re-used in the main heat exchanger system. The refrigerant compressor circuit consists of at least two, and preferably three, mixed refrigerant compression stages. It is contemplated that more than three stages of compression may be found to be desirable for a particular application.
Reference is now made to
The refrigerant circuit of the present invention differs from prior art refrigerant circuits in that the first compression stage (12) is provided with at least two separate parallel compressor bodies, each compressor body having a suction inlet and an outlet. A first distribution means (18) is used for splitting the mass flow of refrigerant gas to the first compression stage (12) across the at least two parallel compressor bodies, such that a first stream (20) of the mass flow of refrigerant gas is fed to a suction inlet (22) of a first compressor body (24) and a second stream (26) of the mass flow of refrigerant gas is fed to a suction inlet (28) of the second compressor body (30). A first merging means (32) is provided downstream of the first and second compressor bodies (24 and 30, respectively) for re-combining the first and second streams (20 and 26, respectively) after the refrigerant gas has been discharged from the first compression stage (12). The refrigerant gas is then directed to flow into a suction inlet (34) of a single compressor body (36) in the second compression stage (14). When the refrigerant circuit (10) includes a third compression stage (16), the refrigerant gas discharged from the second compression stage (14) is directed to flow into a suction inlet (38) of a single compressor body (40) of the third compression stage (16).
In the embodiment illustrated in
Using the refrigerant circuit illustrated in
A further advantage of the present invention is that the actual volumetric flows at the suction inlet to each compression stage are inherently more even, potentially improving the overall efficiency of the refrigerant compressor circuit. As the pressure increases through the compression stages, the density increases and the volumetric flow decreases. By virtue of the compression ratio, the second and third compression stages have lower actual volumetric flow rates than the first (low pressure) compression stage. By splitting the mass flow of refrigerant gas to the first compression stage (12) across at least two separate parallel compressor bodies, the volumetric flow in each of the first and second compressor bodies (24 and 30, respectively) is halved. By way of example, the suction volumetric flow of a first compression stage might typically be about ten times the volumetric flow at the suction inlet of a third compression stage. By splitting the mass flow of refrigerant to the first compression stage across two parallel compressor bodies, each of the first and second compressor bodies in the first compression stage would only require a suction volumetric flow five times the volumetric flow of the third compression stage. By way of further example, for an LNG train producing about 6 mtpa, the suction flow inlet size for a single compressor body used for the first compression stage would need to be about 300,000 m3/h, which is greater than the largest commercially available compressor on the market at this time. Using the process of the present invention, the mass flow of refrigerant to the first stage of compression (12) is split across at least two parallel compressor bodies (24 and 30, respectively), with each of the first and second compressor bodies being capable of compressing about 150,000 m3/h.
The efficiency of each compression stage is dependent upon the rotational speed of the shaft. Usually the optimum compressor stage efficiency is achieved with a higher rotational speed for a smaller suction volumetric flow compared to a larger suction volume. As multiple compressor bodies are often mounted on a common shaft, the overall optimum rotational speed for a given compression string may be a compromise between the ideal speed for each compressor body arranged on that compression string. By having more even suction volumetric flows, multiple compressor bodies may be mounted on the same shaft and operated closer to their optimum speed. Thus the compressor stage efficiencies may be improved when matched with a suitable driver. This leads to lower energy consumption or more production for the same energy input.
In the arrangement illustrated in
Downstream of the last compression stage (14 or 16), the mixed refrigerant is supplied to one or more heat exchangers where the mixed refrigerant is progressively cooled and at least partially liquefied, before being recycled to the main heat exchanger. At least a portion of the cooling of the mixed refrigerant upstream of the main heat exchanger system may be via indirect heat exchange with the pre-cooling refrigerant in one or more pre-cooling heat exchangers (not shown). The pre-cooling refrigerant compressor body (44) may compress pre-cooling refrigerant evaporated by the cooling of the mixed refrigerant. Alternatively or additionally, it may be used to compress pre-cooling refrigerant evaporated in one or more of the pre-cooling heat exchangers used for the purpose of pre-cooling the hydrocarbon feed stream before it enters the main heat exchanger system (42), or for other purposes such as the fractionation of NGLs removed from the natural gas. Thus, the refrigerant being compressed using the pre-cooling refrigerant compressor body (44) could be a substantially pure refrigerant such as propane or ammonia, or alternatively a separate mixed refrigerant with a different composition to the mixed refrigerant evaporated in the main heat exchanger system.
Pre-cooling refrigerant streams evaporated by various heat exchangers at similar pressures are combined and collected using gas liquid/separators such that the pre-cooling refrigerant compressor body (44) is used to compress the combined vapour flows at a plurality of different pressures. The pre-cooling refrigerant compressor body (44) illustrated in
The arrangement illustrated in
The first compressor body (24) and the second compressor body (30) of the first compression stage of compression (12) are mounted co-axially on a second shaft (66) and operated by a second driver (68) in a second compression string (48). The first distribution means (18) is used for splitting the mass flow of mixed refrigerant gas to the first stage of compression (12) substantially evenly across the first compressor body (24) and the second compressor body (30) in an analogous manner to that described above for the refrigerant circuit of
A first intercooling heat exchanger (70) is arranged between the first compression stage (12) and the second compression stage (14) for removing heat of compression from the mixed refrigerant gas. The first merging means (32) for combining the first and second streams (20 and 26, respectively) of the mass flow of refrigerant discharged from the first stage of compression (12) can be either upstream or downstream of the first intercooling heat exchanger (70). When three stages of compression are used, a second intercooling heat exchanger (72) can be provided between the second and third compression stages (14 and 16, respectively) to remove the heat of compression from the mixed refrigerant between the second and third compression stages. A third intercooling heat exchanger (74) can be provided downstream of the third compression stage (16) to remove the heat of compression from the refrigerant after the third compression stage. In the intercooling heat exchangers (70, 72 and 74) the compressed mixed refrigerant exchanges heat with a cooling means, by way of example, an ambient cooling fluid, such as water or air.
In
In
In
A further embodiment is illustrated in
A further embodiment is illustrated in
A further embodiment is illustrated in
In this embodiment, the first compressor body (24) of the first compression stage (12) and the first compressor body (90) of the second compression stage (14) are combined as a first segment (104) and a second segment (106) within a back-to-back compressor body (108). The second compressor body (30) of the first compression stage (12) and the second compressor body (92) of the second compression stage (14) are combined as a first segment (110) and a second segment (112) within a separate back-to-back compressor body (114).
A further embodiment is illustrated in
In each of the illustrated embodiments, the first and second drivers (60 and 68, respectively) need not provide substantially even power draw. Furthermore, in order to maintain the ideal power balance between the first and second shafts (58 and 66, respectively), the first and second streams (20 and 26, respectively) of refrigerant flow to the first and second compressor bodies of the first compression stage (12) may not be identical in that the flow split between the first and second compressor bodies (26 and 30, respectively) may be other than 50%-50%.
It will be apparent to persons skilled in the relevant art that numerous variations and modifications can be made without departing from the basic inventive concepts. All such modifications and variations are considered to be within the scope of the present invention, the nature of which is to be determined from the foregoing description and the appended claims.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2008904872 | Sep 2008 | AU | national |
This application is a continuation of PCT/AU2009/001041, filed on Aug. 13, 2009, which claims priority from Australian Patent Application No. AU 2008904872, filed on Sep. 19, 2008, the disclosures of which are incorporated herein by reference in their entireties.
| Number | Date | Country | |
|---|---|---|---|
| Parent | PCT/AU2009/001041 | Aug 2009 | US |
| Child | 13049608 | US |
