The present invention relates to a process for cooling a gas, or even for liquefying a gas, by means of a refrigeration cycle.
It is common practice to cool a gas by means of a closed refrigeration cycle, which produces cold using a turbine that expands the cycle gas, this turbine being coupled to a compressor that compresses the cycle gas (generally air or nitrogen).
The gas at the outlet of the turbine is generally in gaseous form, with 0% liquid, but sometimes the process requires liquid to be produced, for example in order to feed a thermosiphon. Thus, a liquid phase may be formed, which typically constitutes up to 10 mol % or more of the overall expanded flow. In order to produce such an increase in the liquid fraction at the outlet of the turbine, the expansion ratio of the turbine is kept constant (or at least below 11), but the inlet temperature of the turbine is reduced, typically lower than −115° C. (preferably below −130° C. for a nitrogen cycle).
One aim of the present invention is to present a process that allows the required liquid fraction to be produced at the outlet of the turbine without reducing the temperature at the inlet of the turbine, but optionally by increasing the ratio between the outlet pressure of the turbine and the inlet pressure of the turbine to 11 or above 11 (preferably above 12, or even 16), the two pressures being in bar absolute.
Another aim is to simplify the design of the heat exchanger.
Another aim is to reduce the specific energy of the cycle.
Another aim is to produce one portion of the cycle fluid as a liquid product.
The invention relates to processes such as the recovery of cold from liquefied natural gas, wherein the inlet temperature of the gas passing through the turbine is set by the external conditions (for example if the gas to be expanded has been cooled by vaporization of liquefied natural gas through a heat recovery unit, the inlet temperature of the gas passing through the turbine is set depending on the temperature of the liquefied natural gas to be vaporized (typically −120° C.)).
Units for cooling and optionally for liquefying, for example units producing LNG, nitrogen, oxygen or hydrogen, are cooled by a closed cycle of an intermediate fluid (typically nitrogen with a purity of greater than 90 mol %, preferably greater than 99 mol %, or even 99.9 mol %) comprising at least one compressor, at least one booster, at least one turbine and at least one Joule-Thomson expansion valve. Turbines supply a large portion of the cold energy by extracting energy from the cycle (by extracting enthalpy from the intermediate fluid).
In certain cases, in addition to the production of cold gas, the process requires the production of liquefied gas, either for export or for supplying cold energy needed for cooling and/or liquefying, at least partially, the feed flow, for example in order to feed a thermosiphon.
The liquid is produced either using a Joule-Thomson expansion valve or by the turbine. This production of liquid is more effective if it is performed in the turbine but this requires a turbine with a high expansion ratio.
It is well known, in air separation, for up to 10% liquid to be produced at the outlet of an air turbine. This production is achieved by lowering the inlet temperature and with an expansion ratio of lower than 11.
The problem solved by the present invention is that of producing a liquid fraction at the outlet of the turbine by increasing the ratio between the outlet pressure and the inlet pressure of the turbine. This provides an additional parameter to be adjusted and allows the cycle to be highly effective.
JP2002 164389, WO2014/019698A2 and “Performance and Optimization of Hydrogen Liquefaction Cycles” by Nandi et al, International Journal of Hydrogen Energy, vol. 18, no. 2, 1993, describe the use of a refrigeration cycle that involves the gas to be cooled itself; it is therefore implicit that the feed gas has the same composition as the cycle fluid.
In CN112361713A, the cycle fluid is hydrogen, as is the feed gas. It may be observed that the cycle is used to bring the feed gas to its liquefaction temperature. In the present case, nitrogen cannot bring hydrogen to its liquefaction point since nitrogen would freeze at a higher temperature.
According to one subject of the invention, provision is made for a process for cooling a feed gas, which is hydrogen, by means of a refrigeration cycle, wherein:
According to other optional features:
According to the invention, a refrigeration cycle comprising a cycle fluid (which is nitrogen) is compressed in a cycle compressor, cooled by way of heat exchange with an external source of cold energy (such as liquefied natural gas) and introduced at less than −100° C., preferably less than −120° C., into an expansion turbine in order to extract work from the cycle fluid. The expansion rate of the turbine may be equal to or greater than 11 (preferably greater than 12, or even greater than 16) and therefore the expanded fluid comprises at least 5 mol %, up to 10 mol %, or even up to 20 mol %, of liquid. The expansion rate is the ratio between the inlet pressure and the outlet pressure, the two pressures being in bar absolute.
For a further understanding of the nature and objects for the present invention, reference should be made to the following detailed description, taken in conjunction with the accompanying drawings, in which like elements are given the same or analogous reference numbers and wherein:
In
Then, the gas is optionally cooled in a second heat exchanger E2 in order to form a fluid 3 at −190° C. (gas or liquid) against a liquid fraction 8-1 of the cycle fluid.
The cycle compressor C1 compresses the cycle fluid, which is nitrogen, from a first pressure to a second pressure. The compressed gas 4, which is typically compressed at an ambient temperature, is cooled in a third heat exchanger E3 by way of heat exchange with liquefied natural gas 10 or another fluid to −120° C. The liquefied natural gas 10 is heated, or even vaporized, in the heat exchanger E3, forming a heated fluid 11. The cycle fluid leaves the exchanger E3 at −115° C. as gas 5.
Otherwise, the gas 4 may be cooled in the heat exchanger E1.
The gas 5 is optionally divided into two portions, one 5-1 of which is expanded in a turbine T1, the ratio between the outlet pressure and the inlet pressure exceeding 11. A liquid fraction is produced at the outlet of the turbine, which represents 5 to 20 mol % of the expanded flow 6. The fraction is preferably greater than 5 mol %, if not greater than 7 mol %, if not greater than 9 mol %.
The other portion 5-2 of the gas is cooled in the first heat exchanger E1, having been sent to the exchanger at an intermediate temperature thereof. At the outlet of the first exchanger E1, said portion is expanded as fluid 7 in a valve JT1. Then, the two expanded flows 6,7 are mixed and sent to a phase separator V1, forming a gas 8 and a liquid. The liquid is optionally divided in two, one portion 8-1 being sent to a heat exchanger E2, where it is vaporized. The remainder 8-2 serves as a by-product. The liquid vaporized by vaporizing the portion 8-1 is returned to the separator V1. The gas 8 is heated in the heat exchanger E1, forming the gas 9, which is sent to the compressor C1 at the first pressure.
All of the liquid in the phase separator V1 preferably originates from the turbine T1. The amount of liquid produced by the turbine is controlled by the pressure of the cycle: the level of liquid in the phase separator V1 (thermosiphon) located downstream of the turbine T1 is detected by the level control LC1, which will act in cascade on the pressure control PC1 downstream of the compressor C1, which, in the event of a low level of liquid in the separator V1, will open the make-up valve JT2 for making up the stock of the cycle 12 in order to deliver a gaseous make-up flow from an external source, for example an air separation unit, having the same composition as the cycle fluid. Making up additional cycle stock will allow more liquid 8 to be vaporized, and will therefore increase the pressure at the inlet of the compressor C1. The inlet guide vanes (IGV) of the compressor C1 will open and increase the pressure of the cycle until the liquid level in the phase separator V1 reaches equilibrium. It should be noted that the presence of the flow 5-2 and of the valve JT1 is not essential to the invention. However, if the increase in the pressure of the cycle described above is not sufficient for the liquid level in the separator V1 to reach equilibrium, a second setpoint of the LC1 (liquid level lower than the previous setpoint) may control this valve JT1 in order to further increase the liquid production toward the phase separator V1.
The valve JT1 therefore fulfils two functions: firstly, providing an adjustment that can be more responsive to the amount of liquid in the phase separator V1 and secondly, providing a portion of the production of liquid feeding the phase separator V1 without depending on the performance of the turbine T1 or on the pressure and temperature conditions at the suction end of the turbine (fluid 5, 5-1). Finally, this valve JT1 enables an increase in flexibility of the unit for the production of liquid, in particular for instances of reduced operation.
This passage of the flow 5-2 in the first exchanger E1 and the valve JT1 therefore each enable an increase in reliability and flexibility of the liquid production system.
It is also possible to send the two-phase fluid 6 or the mixture of fluids 6,7 directly to the heat exchanger E1 in order to be heated, without passing through the phase separator.
The invention firstly allows the design of the heat exchanger to be simplified by dispensing with a liquefaction passage dedicated to the production of liquid and secondly allows the specific energy of the cycle to be reduced to 5%, or even to 10%, depending on the arrangements.
It will be understood that many additional changes in the details, materials, steps and arrangement of parts, which have been herein described in order to explain the nature of the invention, may be made by those skilled in the art within the principle and scope of the invention as expressed in the appended claims. Thus, the present invention is not intended to be limited to the specific embodiments in the examples given above.
Number | Date | Country | Kind |
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2300811 | Jan 2023 | FR | national |
2302260 | Mar 2023 | FR | national |
This application claims the benefit of priority under 35 U.S.C. § 119 (a) and (b) to French Patent Application Nos. 2300811, filed Jan. 27, 2023, and U.S. Pat. No. 2,302,260, filed Mar. 10, 2023, the entire contents of which are incorporated herein by reference.