This invention is related to the removal of acid gases from a feed gas. More particularly the invention relates to acid gas removal from high carbon dioxide and hydrogen sulfide containing feed gases. A process is provided for reduced energy requirements in the regeneration of the solvent used to remove the acid gases. In particular, the invention relates to the use of a device to recover energy from high pressure solvent flows and convert the recovered energy to electricity.
Absorption systems are commonly used for the removal of CO2 from natural gas or synthesis gas. A physical solvent such as a dimethylether of polyethylene glycol (DMPEG) can be used to wash out carbon dioxide and other acid gases such as hydrogen sulfide and carbonyl sulfide. DMPEG solvents are used in systems licensed by UOP LLC under the trademark Selexolâ„¢. Cryogenic methanol systems are also known to those skilled in the art for this use including the Rectisolâ„¢ process currently licensed by Lurgi AG. Other physical solvents that may be used include a mixture of N-formyl and N-acetyl morpholine, N-methyl-2-pyrrolidone and sulfolane.
After absorption of carbon dioxide and/or hydrogen sulfide and/or carbonyl sulfide by a physical solvent, the solution is regenerated to remove absorbed gases. The regenerated physical solvent can then be recycled for further absorption. Absorption and regeneration are usually carried out in different columns or drums containing packing or bubble cap tray for efficient operation. Regeneration is generally achieved in two stages. First, the absorbent solution's pressure is reduced so that absorbed carbon dioxide is vaporized from the solution in one or more flash vessels, sometimes terminating with a vacuum flash drum. Next, if thermal regeneration is required, the flashed absorbent is stripped with steam in a stripping regenerating column to remove residual absorbed carbon dioxide. Low carbon dioxide levels are needed in order to achieve the required carbon dioxide specifications for treated gas.
The prior art processes have significant power requirements. The solvent processes employ pressures that range from about 2758 to 7584 kPa (400 to 11 psia) and solvent flow rates that range from 3000 to 20000 gpm. Some of the energy is recoverable from the solvent during pressure let down via turbines. However, conventional turbines have been found to be unreliable and cost prohibitive. The release of relatively large amounts of vapor combined with the high solvent flow rates often means that two or more conventional turbines are required to adequately recover the pump energy. However, the capital costs associated with multiple turbines usually makes this option economically unattractive.
It has now been found that a hydraulic turbocharger can be used to recover energy at a relatively low cost compared to turbines
The present invention involves the use of a solvent stream as the motive fluid at the elevated pressures typical of the process eliminating the high costs previously encountered in regenerating the solvent stream. The motive fluid that is used can be the bottom stream from a carbon dioxide absorber unit or the liquid from the recycle flash drum depending upon the configuration of the system. The pressure of the recycle flash drum can be varied as needed and in certain circumstances the drum can be removed if there is a need for additional energy. The operating pressure of the carbon dioxide absorber ranges from about 2758 to 6550 kPa (400 to 950 psia) so that sufficient energy would be available to be transferred from the fluid exiting the absorber to increase the pressure of another solvent stream. This invention is applicable to any process in which flash or thermal regeneration of a solvent is used in conjunction with a high pressure absorber.
The present invention comprises a process for treating a carbon dioxide containing gas comprised of sending a feed gas containing carbon dioxide through a carbon dioxide absorber unit and contacting it with a lean solvent to produce a loaded solvent containing a majority of said carbon dioxide from said feed gas and a treated gas, regenerating the loaded solvent in a carbon dioxide removal system, and recovering energy from at least one solvent stream to boost pressure of at least one other solvent stream through use of one or more hydraulic turbochargers. There are a number of different configurations that utilize the hydraulic turbocharger that are within the scope of the invention. The hydraulic turbocharger may be used to recover energy from a semi-lean solvent stream that exits the carbon dioxide absorber unit and transfers the energy to pump a lean solvent stream. Alternatively, a hydraulic turbocharger may be used to recover energy from a semi-lean solvent stream that exits the carbon dioxide absorber unit and transfers this energy to pump a semi-lean solvent stream from the carbon dioxide removal system. Also, there may be another hydraulic turbocharger to recover energy from a hydrogen sulfide absorber unit with transfer of this energy to pump a lean solvent stream. Another hydraulic turbocharger can be used instead to recover energy from a hydrogen sulfide concentrator solvent stream to use in pumping a lean solvent stream. The invention also involves a system for removal of carbon dioxide from a carbon dioxide containing solvent comprising a carbon dioxide absorber, a recycle drum, a vacuum flash drum, an eductor and a carbon dioxide venting apparatus. In a particular aspect of the invention, the recovered energy is converted to electricity. This electricity may then be used in various aspects of the process such as driving a pump, powering refrigeration or other aspects of the process. The invention also comprises a system that is designed to run the processes described above.
The invention is generally applicable to physical solvents for which flash or thermal regeneration is used on the solvent stream to produce a solvent stream that contains almost no acid gas. Among the physical solvents that can be used are a dimethylether of polyethylene glycol (DMPEG), methanol, a mixture of N-formyl and N-acetyl morpholine, N-methyl-2-pyrrolidone and sulfolane. Dimethylether of polyethylene glycol is a preferred solvent for use in the present invention.
The present invention includes at least one hydraulic turbocharger to recover energy from a solvent stream and transfer the energy to another solvent stream in a solvent process to remove impurities from gasification synthetic gas or natural gas. The main impurities that are being removed are hydrogen sulfide, carbon dioxide and carbonyl sulfide. The low cost of the hydraulic turbocharger results from the turbine side and pump side being coupled within a single component. There is no need for external equipment to transfer energy from the turbine to the pump, and there is no need for external shaft seals to prevent the process from leaking to the atmosphere. A single stage turbine is beneficial on the turbine side of the turbocharger because single stage turbines are more capable of handling large vaporization rates that are typically found in gas processes than the multiple stage turbines that are often required for conventional power recovery.
In the present invention, a hydraulic turbocharger is used to boost the pressure as necessary in the process solvent streams. In some processes there are often both lean and semi-lean solvent streams whose pressure must be increased from near ambient to over 7500 kPa or to the operating pressure of the absorber. The carbon dioxide absorber bottoms stream which is the highest pressure stream in the carbon dioxide absorption section can be used to boost the pressure of either the lean or semi-lean streams. In one embodiment of the invention, as the pressure of the carbon dioxide absorber bottoms stream is let down in the hydraulic turbocharger, the energy from this stream is used to boost the lean solution pressure. In another embodiment of the invention, the energy from letting down the pressure of the carbon dioxide absorber bottoms stream can be used to boost the pressure of the semi-lean solution. Additional embodiments of the invention employ hydraulic turbochargers at different locations within the process where it is advantageous to recover energy from one solvent stream and use it to increase the pressure of another solvent stream. Other embodiments of the invention employ equipment to convert the high pressure of a solvent stream to electricity which may be used to power elements of the apparatus and go beyond the use of energy recovery to increase the pressure of a solvent stream. The flexibility of the process operation is significantly increased including the use of the recovered energy in the form of electricity at start-up. For example, the electricity may be used to power pumps, refrigeration and other aspects of the process as would be understood by those skilled in the art.
A prior art system is shown in
In
In
In
In
Other embodiments may be employed that employ the basic principles of the present invention.
While the following is described in conjunction with specific embodiments, it will be understood that this description is intended to illustrate and not limit the scope of the preceding description and the appended claims.
A first embodiment of the invention is a process for treating a carbon dioxide and/or hydrogen sulfide containing gas comprising a) sending a feed gas containing carbon dioxide and hydrogen sulfide through a carbon dioxide and/or hydrogen sulfide absorber unit containing a lean solvent to produce a loaded solvent containing a majority of the carbon dioxide and/or hydrogen sulfide from the feed gas and a treated gas; b) regenerating the loaded solvent in a carbon dioxide and or hydrogen sulfide removal system; and c) recovering energy from at least one solvent stream to boost pressure of at least one other solvent stream wherein at least one hydraulic turbocharger is used to recover the energy wherein the energy is recovered in a form of electricity. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph wherein the carbon dioxide and or hydrogen sulfide regeneration system comprises a recycle flash drum, a carbon dioxide vent drum and a carbon dioxide vacuum drum. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph wherein a hydraulic turbocharger is used to recover energy from a solvent stream that exits the carbon dioxide absorber unit and transfers the energy to pump a lean solvent stream. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph wherein a hydraulic turbocharger is used to recover energy from a solvent stream that exits the carbon dioxide and/or hydrogen sulfide absorber unit and transfers the energy to pump a semi-lean solvent stream from the carbon dioxide removal system. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph further comprising using a second hydraulic turbocharger to recover energy from a hydrogen sulfide absorber and transfer the energy to pump a lean solvent stream to the carbon dioxide absorber unit. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph further comprising using a second hydraulic turbocharger to recover energy from a hydrogen sulfide concentrator solvent stream to use in pumping a lean solvent stream. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph wherein the solvent is selected from the group consisting of dimethylether of polyethylene glycol, methanol, a mixture of N-formyl and N-acetyl morpholine, N-methyl-2-pyrrolidone and sulfolane.
A second embodiment of the invention is a system for treating a carbon dioxide containing gas comprising a carbon dioxide absorber unit containing a lean solvent to produce a loaded solvent containing a majority of the carbon dioxide from carbon dioxide containing gas and a treated gas; a carbon dioxide removal system and at least one hydraulic turbocharger is used to recover energy from at least one solvent stream and the energy is then converted to electricity. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the second embodiment in this paragraph wherein a hydraulic turbocharger is used to recover energy from a semi-lean solvent stream that exits the carbon dioxide absorber unit and transfers the energy to pump a lean solvent stream. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the second embodiment in this paragraph wherein a hydraulic turbocharger is used to recover energy from a semi-lean solvent stream that exits the carbon dioxide absorber unit and transfers the energy to pump a semi-lean solvent stream from the carbon dioxide removal system. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the second embodiment in this paragraph further comprising using a second hydraulic turbocharger to recover energy from a hydrogen sulfide absorber unit and transfer the energy to pump a lean solvent stream to the carbon dioxide absorber unit. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the second embodiment in this paragraph further comprising using a second hydraulic turbocharger to recover energy from a hydrogen sulfide concentrator solvent stream to use in pumping a lean solvent stream. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the second embodiment in this paragraph wherein the solvent is selected from the group consisting of dimethylether of polyethylene glycol, methanol, a mixture of N-formyl and N-acetyl morpholine, N-methyl-2-pyrrolidone and sulfolane.
Without further elaboration, it is believed that using the preceding description that one skilled in the art can utilize the present invention to its fullest extent and easily ascertain the essential characteristics of this invention, without departing from the spirit and scope thereof, to make various changes and modifications of the invention and to adapt it to various usages and conditions. The preceding preferred specific embodiments are, therefore, to be construed as merely illustrative, and not limiting the remainder of the disclosure in any way whatsoever, and that it is intended to cover various modifications and equivalent arrangements included within the scope of the appended claims.
In the foregoing, all temperatures are set forth in degrees Celsius and, all parts and percentages are by weight, unless otherwise indicated.
This application claims priority from Provisional Application No. 62/015,837 filed Jun. 23, 2014, the contents of which are hereby incorporated by reference.
Number | Date | Country | |
---|---|---|---|
62015837 | Jun 2014 | US |