Split refrigerant compressor for the liquefaction of natural gas

Abstract

A compressor system is disclosed, including 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; 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 the third gas inlet and fourth gas inlet of the second compressor unit.

Claims

1. A compressor system for compressing a first refrigerant comprising: a first compressor unit comprising: a first gas inlet that is configured to receive the first refrigerant at a first gas pressure level; a second gas inlet that is configured to receive the first refrigerant at a second gas pressure level and is located downstream of the first gas inlet; and a gas discharge located downstream of the second gas inlet; and a second compressor unit comprising: a third gas inlet that is configured to receive the first refrigerant at a third gas pressure level; a fourth gas inlet that is configured to receive the first refrigerant at a fourth gas pressure level and is located downstream of the third gas inlet; wherein the gas discharge of the first compressor unit is fluidly coupled to the fourth gas inlet of the second compressor unit; wherein the fourth gas pressure level is higher than the first gas pressure level and higher than the second gas pressure level, and the second gas pressure level is higher than the first gas pressure level; and wherein (i) if the second gas pressure level is lower than the third pressure level, then the flow rate through a compression stage from the third gas inlet to fourth gas inlet is reduced, and (ii) if the second gas pressure level is higher than the third pressure level, then the flow rate through a compression stage from the second gas inlet to fourth gas inlet is reduced.

2. The compressor system of claim 1, wherein the second compressor unit has only the third gas inlet and the fourth gas inlet as gas inlets.

3. The compressor system of claim 1, wherein the first compressor unit has a first compressor stage with a single impeller and a second compressor stage with a single impeller, and wherein the second compressor unit has a third compressor stage with a single impeller and a fourth compressor stage with two impellers.

4. The compressor system of claim 1, wherein the first compressor unit is housed in a first casing, and the second compressor unit is housed in a second casing.

5. The compressor system of claim 1, wherein the first straight compressor unit and the second compressor unit are housed in a common casing.

6. The compressor system of claim 5, wherein a first impeller group consisting of impellers included in the first compressor unit and a second impeller group consisting of impellers included in the second compressor unit are positioned in line and in a back-to-back arrangement.

7. The compressor system of claim 1, wherein the first compressor unit and the second compressor unit are arranged and control led to rotate at substantially the same rotational speed.

8. The compressor system of claim 1, wherein the first compressor unit and the second compressor unit are arranged and controlled to rotate at different rotational speeds.

9. The compressor system of claim 8, further comprising a gearbox arranged between the first compressor unit and the second compressor unit.

10. The compressor system of claim 8, wherein the first compressor unit is driven by a first driver and the second compressor unit is driven by a second driver.

11. A refrigerant system for liquefaction of natural gas, comprising: a natural gas line; and at least a first refrigerant circuit comprising the compressor system of claim 1; a high-temperature heat exchange arrangement for discharging heat from a first refrigerant delivered by the compressor system; and a low-temperature heat exchange arrangement, wherein the first refrigerant 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, wherein the low-temperature temperature heat exchange arrangement comprises heat exchangers, each heat exchanger fluidly coupled with each gas inlet in the compressor system.

12. A method for compressing a first refrigerant by using a first compressor unit comprising: a first gas inlet; a second gas inlet located downstream of the first gas inlet; and a gas discharge located downstream of the second gas inlet and a second compressor unit comprising: a third gas inlet; a fourth gas inlet located downstream of the third gas inlet, the method comprising: introducing a single gas flow of the first refrigerant at a first gas pressure level into the first gas inlet; introducing a single gas flow of the first refrigerant at a second gas pressure level into the second gas inlet; introducing a gas flow of the first refrigerant at a third gas pressure level into the third gas inlet; introducing a gas flow of the first refrigerant at a fourth gas pressure level into the fourth gas inlet; and introducing a gas flow of the first refrigerant from the first compressor unit into the fourth gas inlet of the second compressor unit, wherein the fourth gas pressure level is higher than the first gas pressure level and higher than the second gas pressure level, and the second gas pressure level is higher than the first gas pressure; and wherein (i) if the second gas pressure level is lower than the third pressure level, then the flow rate through a compression stage from the third gas inlet to fourth gas inlet is reduced, and (ii) if the second gas pressure level is higher than the third pressure level, then the flow rate through a compression stage from the second gas inlet to fourth gas inlet is reduced.

13. A natural gas liquefaction method comprising: removing heat from a refrigerant flow of a first refrigerant compressed by the compressor system of claim 1; dividing the refrigerant flow into a first partial stream, a second partial stream, a third partial stream and a fourth partial stream; expanding each partial stream at a respective pressure level; 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 partial stream and the second partial stream into the first gas inlet and the second gas inlet of the first compressor unit of the compressor system respectively; introducing the third partial stream and the fourth partial stream into the third gas inlet and the fourth gas inlet of a second compressor unit of the compressor system respectively; and introducing the first refrigerant compressed by the first compressor unit into the fourth gas inlet of the second compressor unit.

14. The compressor system of claim 1, wherein a single gas flow of the first refrigerant at the first gas pressure level and a single gas flow of the first refrigerant at the second gas pressure level are provided to the first compressor unit.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) 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:

(2) FIG. 1 illustrates a schematic of an exemplary embodiment of an LNG system using a refrigerant compressor with side streams;

(3) FIGS. 2, 3 and 4 illustrate embodiments of a refrigerant compressor system according to the present disclosure;

(4) FIGS. 5 to 8 illustrate embodiments of the casing and driver arrangement for a compressor system according to the present disclosure;

(5) FIGS. 9, 10, 11 and 12 illustrate current art arrangements of side stream compressors for LNG applications, described above.

DETAILED DESCRIPTION

(6) 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.

(7) 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.

(8) 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.

(9) 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.

(10) 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.

(11) A schematic of the exemplary LNG system according to the C3-MR technology is shown in FIG. 1. The LNG system, globally labeled 1, is known to those skilled in the art and herein only a general description of the system will be given, for a better understanding of the novel embodiments disclosed herein.

(12) The system 1 includes a propane pre-cooling section 3 and a mixed refrigerant section 5.

(13) 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.

(14) 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.

(15) In the exemplary layout of FIG. 1, the mixed-refrigerant section 5 comprises mixed refrigerant compressors 9A, 9B, 9C, which can be driven by one or more drivers. In some embodiments the mixed refrigerant compressors 9A, 9B are driven by a first driver 11, e.g. a gas turbine engine. The third, high-pressure mixed refrigerant compressor 9C can be driven into rotation by a second driver 13, e.g. a further gas turbine engine. The second driver 13 can be used also to drive a propane compressor system or part thereof, as will be described later on and as schematically shown in FIG. 1.

(16) Reference number 15 indicates a main cryogenic heat exchanger (MCHE), wherein the chilled mixed refrigerant exchanges heat against the natural gas.

(17) 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 FIG. 1 four pressure levels are used. A second set of precooling heat exchangers 19A-19D is further provided, wherein the chilled propane at the same four pressure levels exchanges heat against the natural gas flowing in line 7, to precool the natural gas prior to entering the MCHE 15.

(18) 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.

(19) 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.

(20) 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.

(21) 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.

(22) 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.

(23) 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 FIG. 2. The compressor system is again labeled 21 as a whole. In the embodiment of FIG. 2, the compressor system 21 comprises a first compressor unit 51 and a second compressor unit 53.

(24) 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.

(25) 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.

(26) In FIG. 2 the first compressor unit 51 comprises two compressor stages 51.1 and 51.2. By way of example, each compressor stage 51.1 and 51.2 comprises one impeller. The use of more than one impeller for one or both stages 51.1 and 51.2 is not excluded, however.

(27) 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.

(28) As shown in FIG. 2, the first compressor unit 51 is a straight through compressor unit, wherein a single gas flow for each pressure level is provided. I.e. the first gas inlet 22C receives the full gas flow at a first pressure, and the second gas inlet 22B receives the full gas flow at the second pressure. The compressor unit discharge 52 receives a gas flow consisting of the gas flow entering the first gas inlet 22C and the second gas inlet 22B. The same straight through layout is provided in further embodiments disclosed here below, wherein a single gas flow, i.e. a single gas inlet is provided for each pressure level.

(29) 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.

(30) 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.

(31) 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.

(32) As shown in FIG. 2, also the second compressor unit 53 is a straight through compressor unit, wherein a single gas flow for each pressure level is provided. I.e. the third gas inlet 22D receives the full gas flow at a third pressure, and the fourth gas inlet 22A receives the full gas flow at the fourth pressure.

(33) The overall structure of the compressor system 21 is simpler than in the arrangements of the current art (FIG. 10). Also the control of the compressor system 21 is simpler than in the prior art (FIGS. 11, 12). In particular, with respect to the arrangement of FIGS. 11 and 12, in the arrangement of FIG. 2 the compressor units 51 and 53 have a single delivery side 23 in direct fluid communication with the high-temperature heat exchanger, such that control of the compressor system 21 is made simpler.

(34) With respect to FIG. 10, the compressor system of the present disclosure avoids the use of a dual-flow compressor arrangement, where gas side streams at the same pressure are split among two separate gas inlets. A structure is thus obtained, which is simpler than that of the current art systems using a dual flow or parallel flow arrangements.

(35) FIG. 3 illustrates a further embodiment of a compressor system according to the present disclosure. The same references as in FIG. 2 designate the same or equivalent parts, components or elements of the compressor system 21. The difference between FIGS. 2 and 3 concerns the arrangement of the low pressure gas inlet 22D and medium pressure gas inlet 22C, the positions whereof are reversed with respect to the arrangement of FIG. 2. In FIG. 3 the first compressor unit 51 receives low pressure (LP) propane at the gas inlet 22D and high pressure (HP) propane at the gas inlet 22B. The second compressor unit 53 receives medium pressure (MP) propane at the gas inlet 22C and very high pressure (HHP) propane at the gas inlet 22A.

(36) 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.

(37) 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.

(38) A further embodiment of the compressor system 21 according to the present disclosure is shown in FIG. 4. The same references are used as in FIGS. 2 and 3 to designate the same or equivalent parts, components or elements. The arrangement of FIG. 4 differs from the arrangement of FIG. 3 mainly because the arrangement of the gas inlets 22C and 22B is reversed.

(39) In FIG. 4 the first compressor unit 51 receives low pressure (LP) propane at gas inlet 22D and medium pressure (MP) propane at gas inlet 22C, while the second compressor unit 53 receives high pressure (HP) propane at gas inlet 22B and very high pressure (HHP) propane at gas inlet 22A.

(40) 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.

(41) 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.

(42) As can be appreciated from FIGS. 2 to 4, in all embodiments the flow rate through the most critical compression stage from the HP to HHP is reduced. In fact, while in the basic current art embodiment of FIG. 9 the compressor stage which compresses the gas from HP to HHP processes the total flow rate given by the sum of the flow rates through gas inlets 122D, 122C, 122B, in the embodiment of FIG. 2, for instance, the compressor stage 51.2 only processes the flow rate of gas inlets 22C and 22B. In the embodiment of FIG. 3, the critical compressor stage 51.2 only processes the flow rate of gas inlets 22D and 22B. Finally, in the embodiment of FIG. 4 the critical compressor stage 53.1 only processes the flow rate of gas inlet 22B.

(43) With respect to the current art arrangements of FIGS. 11 and 12, the embodiments disclosed herein provide for a single outlet or delivery side 23 of the compressor system 21, such that control of the operation of the compressor units 51 and 53 is made simpler and more reliable.

(44) FIGS. 2 to 4 illustrate possible examples of compressor stage arrangements and relevant fluid couplings therebetween. The various arrangements can be embodied in different configurations as far as the number of compressor casings, driving shafts, drivers and connecting ducts are concerned. Possible configurations are shown in FIGS. 5 to 8.

(45) FIG. 5 illustrates a compressor system 21 comprising two separate compressor casings 61, 63. The compressor casing 61 can contain the compressor unit 51 of any one of FIGS. 2, 3 and 4. The compressor casing 63 can contain the compressor unit 53 of any one of FIGS. 2, 3 and 4. Since the arrangement of FIG. 5 can refer to any one of the configurations of FIGS. 2, 3 and 4, the gas inlets of the two compressor casings 61 and 63 are generically indicated as I1, I2, I3, I4, respectively the first, second, third and fourth gas inlets. The discharge 52 of compressor unit 51 is fluidly coupled to the gas inlet I3 of compressor unit 53. Reference number 67 designates a driver which rotates the two compressor units 51, 53 through shaft 65.

(46) FIG. 6 illustrates a compressor system 21 comprising two compressor units 51, 53, which are driven into rotation by separate drivers 65A, 65B through shafts 67A, 67B and can thus operate at different rotational speeds. Gas inlets are shown at I1, I2, I3, I4. The outlet of compressor unit 51 is fluidly coupled to the gas inlet I3 of compressor unit 53.

(47) FIG. 7 illustrates an arrangement similar to FIG. 5, wherein a gear box 69 is arranged between compressor unit 51 and compressor unit 53 such that the two compressor units can rotate at different rotation speeds. The remaining reference numbers designate the same parts, elements or components as in FIG. 5.

(48) A yet further embodiment of the compressor system 21 is shown in FIG. 8. The two compressor units 51, 53 are arranged in a single casing 62 in a back-to-back configuration. The fluid connection between the outlet of compressor unit 51 and the gas inlet I3 of compressor unit 51 can be located inside or outside the casing 62.

(49) 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.

(50) 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.