The present disclosure concerns systems and methods for compressing a gaseous fluid, e.g. a refrigerant in a refrigeration circuit. Embodiments disclosed herein specifically refer to systems for the production of liquefied natural gas (LNG), using one or more refrigerant circuits.
Combustion of conventional fuels is essential in several industrial processes. Recently, in an effort to reduce the environmental impact of traditional liquid or solid fossil fuels, such as gasoline, diesel and carbon, the use of natural gas has been increased. Natural gas represents a cleaner, less polluting source of energy.
While the use of natural gas overcomes some of the disadvantages and drawbacks of conventional fossil fuels, storage and transport of natural gas poses difficulties. For transport purposes, where no gas pipelines are available, natural gas is conventionally chilled and converted into liquefied natural gas. Several thermodynamic cycles have been developed for converting natural gas in liquefied natural gas. The thermodynamic cycles usually include one or more compressors which process one or more refrigerant fluids. The refrigerant fluids undergo cyclic thermodynamic transformations to remove heat from the natural gas until this latter is finally converted in liquid phase. In some known LNG systems, pre-cooling and cooling circuits are provided, which are arranged e.g. in cascade or in other possible combinations. Different refrigerant fluids are used to chill the natural gas and/or to pre-cool another refrigerant fluid, which in turn chills the natural gas.
Several LNG systems provide for a refrigerant fluid to be compressed and expanded at several pressure levels, to exchange heat with the natural gas to be liquefied and/or with another refrigerant gas, at different pressure levels, to improve the overall efficiency of thermodynamic cycle. The compressor is in this case provided with several inlets at different pressure levels. Gas inlets at different pressure levels between the suction pressure and the delivery pressure of the refrigerant gas are also referred to as side streams.
The sequentially arranged impellers of a compressor with side streams process variable gas flow rates. Usually, one impeller is arranged at the suction side of the compressor and one additional impeller is arranged downstream of each side stream. Thus, several impellers process variable gas flow rates. The overall performance of the compressor is limited by one of the compressor phases, due to the high flow rate and low pressure ratio. Usually, in compressors having a suction side and three side streams, i.e. four compressor phases, the third phase is the most critical one. Several alternative arrangements of the side-stream compressor have been designed with an aim at solving or alleviating the above-mentioned problem. The current art arrangements, however, do not satisfactorily address this drawback and are affected by other limits and disadvantages.
In order to increase the performances of the compressor system 121, according to a further embodiment of the current art a parallel propane compressor arrangement as shown in
Moreover, since the flow rate of all gas inlets is reduced by 50% with respect to the total flow rate, some of the impellers operate under operating conditions which are below the optimal operating point. This factor adversely affects the overall efficiency of the compressor system 121.
A yet further arrangement of the current art is shown in
A yet further layout according to the current art is shown in the schematic of
The flow rate of the very high pressure gas inlet 122A is rather low, which means that the compressor including the gas inlet 122A (compressor 141B in
A need therefore exists, for an improved side-stream compressor system, in particular for LNG applications.
According to one aspect, a compressor system is disclosed herein, comprising a first compressor unit having: at least a first gas inlet at a first gas pressure level; a second gas inlet at a second gas pressure level; and a gas discharge. The compressor system further comprises a second compressor unit having: at least a third gas inlet at a third gas pressure level; a fourth gas inlet at a fourth gas pressure level; and a gas delivery. The gas discharge of the first compressor unit is fluidly coupled to one of said third gas inlet and fourth gas inlet of the second compressor unit. The fourth gas pressure level can be higher than the first gas pressure level and/or higher than the third gas pressure level. The second gas pressure level can be higher than the first gas pressure level and/or lower than the fourth gas pressure level.
A more efficient distribution of the side stream flow rates is thus obtained, which improves the overall performances of the compressor system with respect to the compressor systems of the prior art.
Each compressor unit can be comprised of one or more centrifugal compressors, e.g. a multi-stage centrifugal compressor.
According to a further aspect, the present disclosure concerns a refrigerant system for liquefaction of natural gas flowing in a natural gas line. The refrigerant system comprises at least a first refrigerant circuit comprised of: a compressor system as above described; a high-temperature heat exchange arrangement for discharging heat from a refrigerant fluid, delivered by the compressor system, to a heat sink; a low-temperature heat exchange arrangement, where the refrigerant fluid is in heat exchange relationship with at least one of a second refrigerant and natural gas flowing in the natural gas line, to remove heat therefrom.
According to another aspect, the subject matter disclosed herein concerns a method for compressing a gaseous fluid, comprising the following:
delivering a first plurality of gas streams at different pressure levels to a first plurality of gas inlets of a first compressor unit;
delivering a second plurality of gas streams at different pressure levels to a second plurality of gas inlets of a second compressor unit;
delivering partly compressed gas from a discharge of the first compressor unit to one of the second plurality of gas inlets of the second compressor unit;
delivering a total compressed gas flow from a gas delivery of the second compressor unit.
More specifically, disclosed herein is also a natural gas liquefaction method, comprising the following:
delivering a compressed refrigerant flow from a compressor system to a heat sink and removing heat therefrom;
dividing the refrigerant flow from the heat sink into a first plurality of partial streams and a second plurality of partial streams;
expanding each partial stream at a respective pressure level; whereby each partial stream is expanded at a pressure level different from the other partial streams;
removing heat from at least one of a second refrigerant and natural gas flowing in a natural gas line by means of the partial streams;
introducing the first plurality of partial streams in a respective plurality of first gas inlets of a first compressor unit of the compressor system; and introducing the second plurality of partial streams in a respective plurality of second gas inlets of a second compressor unit of the compressor system;
introducing refrigerant compressed by the first compressor unit into one of the plurality of second gas inlets of the second compressor unit.
Features and embodiments are disclosed here below and are further set forth in the appended claims, which form an integral part of the present description. The above brief description sets forth features of the various embodiments of the present invention in order that the detailed description that follows may be better understood and in order that the present contributions to the art may be better appreciated. There are, of course, other features of embodiments of the invention that will be described hereinafter and which will be set forth in the appended claims. In this respect, before explaining several embodiments of the invention in details, it is understood that the various embodiments of the invention are not limited in their application to the details of the construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. Embodiments of the invention are capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
As such, those skilled in the art will appreciate that the conception, upon which the disclosure is based, may readily be utilized as a basis for designing other structures, methods, and/or systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
A more complete appreciation of the disclosed embodiments of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
The following detailed description of the exemplary embodiments refers to the accompanying drawings. The same reference numbers in different drawings identify the same or similar elements. Additionally, the drawings are not necessarily drawn to scale. Also, the following detailed description does not limit embodiments of the invention. Instead, the scope of embodiments of the invention is defined by the appended claims.
Reference throughout the specification to “one embodiment” or “an embodiment” or “some embodiments” means that the particular feature, structure or characteristic described in connection with an embodiment is included in at least one embodiment of the subject matter disclosed. Thus, the appearance of the phrase “in one embodiment” or “in an embodiment” or “in some embodiments” in various places throughout the specification is not necessarily referring to the same embodiment(s). Further, the particular features, structures or characteristics may be combined in any suitable manner in one or more embodiments.
In the following description reference will specifically be made to an exemplary embodiment of an LNG system, wherein a side-stream compressor system is used. More specifically, reference will be made to a so-called C3-MR liquefaction system, using a mixed refrigerant (MR) circuit and a propane (C3) circuit. The propane circuit is used as a precooling for the natural gas as well as for the mixed refrigerant. This technology is usually referred to as propane/mixed refrigerant technology. It shall however be understood that aspects of the subject matter disclosed herein can be implemented in other LNG systems using a refrigerant processed by a compressor system including side streams. For instance, embodiments disclosed herein can be used in so-called dual-mixed refrigerant circuits (DMR circuits), wherein a second mixed refrigerant is used for pre-cooling purposes, rather than propane. In other embodiments, the LNG system can use an APX process, which has substantially the same layout as a C3-MR process, with the addition of a nitrogen refrigerant subcooling cycle.
Thus, the C3-MR system described here below shall be understood as being just one example of several possible LNG systems, wherein the subject matter disclosed herein can be used.
It shall further be understood that advantages of a compressor system as disclosed herein can be usefully exploited also in other systems and methods for gas processing, whenever a compressor system with side streams is used.
A schematic of the exemplary LNG system according to the C3-MR technology is shown in
The system 1 includes a propane pre-cooling section 3 and a mixed refrigerant section 5.
Both sections 3 and 5 comprise a refrigerant circuit including a compressor system, a high-temperature heat exchanger arrangement for discharging heat from the refrigerant fluid circulating in the refrigerant circuit, a low temperature heat exchange arrangement, where the refrigerant fluid is in heat exchange relationship with another refrigerant and/or with the natural gas to be liquefied.
The natural gas flows in a main line 7 from a natural gas inlet 7A to a liquefied natural gas outlet 7B. The main line 7 extends through the propane pre-cooling section 3 and through the mixed refrigerant section 5.
In the exemplary layout of
Reference number 15 indicates a main cryogenic heat exchanger (MCHE), wherein the chilled mixed refrigerant exchanges heat against the natural gas.
The compressed mixed refrigerant delivered by compressor 9C is precooled in a first set of precooling heat exchangers 17A-17D, by exchanging heat against chilled propane at a plurality of different pressure levels. In the exemplary embodiment of
The compressed propane is provided by a propane compressor system 21. A delivery 23 of the propane compressor system 21 is fluidly coupled with heat exchangers and condensers 25, 27, 29, wherefrom compressed and condensed propane is delivered at the first set of precooling heat exchangers 17A-17D. The heat exchangers and condensers 25, 27, 29 form a high-temperature heat exchange arrangement, where heat is removed from the compressed propane by heat exchange against air, water or another cooling medium, defining a heat sink.
Expansion valves 31A-31D and 33A-33D are provided, for sequentially expanding the propane at the four pressure levels. References 22A-22D designate four gas inlets of the propane compressor system 21, which are fluidly coupled to the precooling, heat exchangers 17A-17D and 19A-19D of the first set and second set, respectively. The first inlet 22D at the lowest pressure level is usually referred to as suction side of the compressor system 21, while the other gas inlets 22C, 22B, 22A are usually referred to as side-streams. In the context of the present disclosure, the suction side and the side streams are globally referred to as gas inlets.
The precooling heat exchangers 17A-17D, 19A-19D form a low temperature heat exchange arrangement, where propane is in heat exchange relationship with both the mixed refrigerant and the natural gas for pre-cooling purposes.
The precooling heat exchangers 17D, 19D at the lowest pressure are fluidly coupled to the suction side, i.e. to the lowest pressure inlet 22D of the propane compressor system 21. The precooling heat exchangers 17C, 19C, 17B, 19B and 17A, 19A at gradually increasing pressure levels are fluidly coupled to the propane compressor system 21 through the side stream inlets 22C, 22B and 22A, respectively. Here below, the pressure levels at the inlets 22D, 22C, 22B and 22A will be also referred to as: low pressure (LP), medium pressure (MP), high pressure (HP) and very high pressure (HHP) respectively.
The compressor system 21 usually comprises four compression stages and four or more impellers, i.e. at least one impeller for each gas inlet 22D-22A. In some embodiments, the compressor system 21 comprises five impellers. The possibility of having more than five impellers is not excluded.
An embodiment according to the present disclosure, aimed at solving or alleviating at least one of the above discussed drawbacks of the current art is shown in
In general, each compressor unit 51, 53 comprises at least two gas inlets. Since in the presently described embodiments the precooling circuit comprises four propane pressure levels, the first compressor unit 51 comprises a first gas inlet and a second gas inlet; the second compressor unit 53 comprises a third gas inlet and a fourth gas inlet.
It shall be understood that utilizing more than four propane pressure levels is not excluded, in which case at least one of the compressor units 51, 53 may include more than two gas inlets.
In
The first compressor stage 51.1 has a first gas inlet 22C receiving propane at the medium propane pressure MP. The second compressor stage 51.2 receives partly compressed propane from the first compressor stage 51.1 and propane from the side stream or second gas inlet 22B at the high propane pressure HP.
As shown in
The second compressor unit 53 comprises a third compressor stage 53.1 and a fourth compressor stage 53.2. The third compressor stage 53.1 can comprise a single impeller, while in this exemplary embodiment the fourth compressor stage 53.2 comprises two impellers. Any different number of impellers for each compressor stage can be envisaged, however.
The third compressor stage 53.1 receives a propane side stream at the third gas inlet 22D at the low propane pressure LP. The fourth compressor stage 53.2 receives a propane side stream at the fourth gas inlet 22A at the very high propane pressure HHP. The fourth compressor stage 53.2 further receives the total flow rate delivered by the discharge 52 of the first compressor unit 51, consisting of the gas flows from the first gas inlet 22C and the second gas inlet 22B.
Thus, in the first compressor stage 51.1 the gas is compressed from medium pressure MP to high pressure HP, while in the second compressor stage 51.2 the gas is compressed from high pressure HP to very high pressure MP. The third compressor stage 53.1 compresses the gas from low pressure LP to very high pressure HHP, while the fourth compressor stage 53.2 compresses the gas from the very high pressure HHP to the upper propane pressure in the propane cycle.
As shown in
The overall structure of the compressor system 21 is simpler than in the arrangements of the current art (
With respect to
The discharge 52 of the first compressor unit 51 is fluidly coupled to the gas inlet arranged between the third compressor stage 53.1 and the fourth compressor stage 53.2. The compressed propane stream from the first compressor unit 51 is mixed with the very high propane pressure stream at gas inlet 22A and delivered through the last compressor stage 53.2.
Thus, in the first compressor stage 51.1 the gas is compressed from pressure LP to pressure HP, while in the second compressor stage 51.2 the gas is compressed from pressure HP to pressure HHP. The third compressor stage 53.1 compresses the gas from pressure MP to pressure HHP, while the fourth compressor stage 53.2 compresses the gas from pressure HHP to the upper propane pressure in the propane cycle.
A further embodiment of the compressor system 21 according to the present disclosure is shown in
In
The discharge 52 of the first compressor unit 51 is fluidly coupled to the gas inlet arranged between the third compressor stage 53.1 and the fourth compressor stage 53.2. The compressed propane flow from the first compressor unit 51 is mixed with the propane at very high pressure at the gas inlet 22A and delivered through the last compressor stage 53.2.
Thus, in the first compressor stage 51.1 the gas is compressed from pressure LP to pressure MP, while in the second compressor stage 51.2 the gas is compressed from pressure MP to pressure HHP. The third compressor stage 53.1 compresses the gas from pressure HP to pressure HHP, while the fourth compressor stage 53.2 compresses the gas from HHP to the upper propane pressure in the propane cycle.
As can be appreciated from
With respect to the current art arrangements of
A yet further embodiment of the compressor system 21 is shown in
While the disclosed embodiments of the subject matter described herein have been shown in the drawings and fully described above with particularity and detail in connection with several exemplary embodiments, it will be apparent to those of ordinary skill in the art that many modifications, changes, and omissions are possible without materially departing from the novel teachings, the principles and concepts set forth herein, and advantages of the subject matter recited in the appended claims. Hence, the proper scope of the disclosed innovations should be determined only by the broadest interpretation of the appended claims so as to encompass all such modifications, changes, and omissions. In addition, the order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments.
This written description uses examples to disclose the invention, including the preferred embodiments, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.
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102016000080745 | Aug 2016 | IT | national |
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PCT/EP2017/068893 | 7/26/2017 | WO | 00 |
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WO2018/024576 | 2/8/2018 | WO | A |
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Number | Date | Country | |
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20190271502 A1 | Sep 2019 | US |