Hydrocarbon gas processing

Abstract

A process and an apparatus are disclosed for the recovery of components from a hydrocarbon gas stream which is divided into first and second streams. The first stream is cooled, expanded to lower pressure, and supplied to a fractionation tower. The second stream is cooled and separated into vapor and liquid streams. The vapor stream is divided into two portions. A first portion is cooled, expanded to tower pressure, and supplied to the tower at an upper mid-column feed position. The second portion and the liquid stream are expanded to tower pressure and supplied to the tower. After heating, compressing, and cooling, a portion of the tower overhead vapor is cooled, expanded, and supplied to the tower at the top feed position. The quantities and temperatures of the feeds to the tower maintain the overhead temperature of the tower whereby the major portion of the desired components is recovered.

Claims

1. In a process for the separation of a gas stream containing methane, C2 components, C3 components, and heavier hydrocarbon components into a volatile residue gas fraction and a less volatile fraction containing a portion of said C2 components, C3 components, and heavier hydrocarbon components or said C3 components and heavier hydrocarbon components, wherein (a) said gas stream is cooled under pressure to provide a cooled stream; (b) said cooled stream is expanded to a lower pressure whereby said cooled stream is further cooled; and (c) said further cooled stream is directed into a distillation column and fractionated at said lower pressure whereby the components of said less volatile fraction are recovered; wherein prior to cooling, said gas stream is divided into first and second streams; (1) said first stream is cooled to form a condensed first stream; (2) said condensed first stream is expanded to said lower pressure to form an expanded condensed first stream that is thereafter supplied to said distillation column at a mid-column feed position; (3) said second stream is cooled under pressure to form a partially condensed second stream; (4) said partially condensed second stream is separated thereby to provide a vapor stream and at least one liquid stream; (5) said vapor stream is divided into first and second portions; (6) said first portion is cooled to form a condensed first portion; (7) said condensed first portion is expanded to said lower pressure to form an expanded condensed first portion that is thereafter supplied to said distillation column at an upper mid-column feed position above said mid-column feed position; (8) said second portion is expanded to said lower pressure to form an expanded second portion that is supplied to said distillation column at a lower mid-column feed position below said mid-column feed position; (9) at least a portion of said at least one liquid stream is expanded to said lower pressure to form an expanded liquid stream that is supplied to said distillation column at another lower mid-column feed position below said mid-column feed position; (10) a distillation vapor stream is collected from an upper region of said distillation column and heated to form a heated distillation vapor stream, said heating thereby to supply at least a portion of said cooling of steps (1), (3), and (6); (11) said heated distillation vapor stream is compressed to higher pressure, cooled, and thereafter divided into said volatile residue gas fraction and a compressed recycle stream; (12) said compressed recycle stream is cooled to form a condensed compressed recycle stream, said cooling thereby to supply at least a portion of said heating of step (10); (13) said condensed compressed recycle stream is expanded to said lower pressure to form an expanded condensed compressed recycle stream that is thereafter supplied to said distillation column at a top feed position; and (14) portions of components in said less volatile fraction are recovered.

2. The process according to claim 1 wherein (1) said gas stream is cooled under pressure to form a partially condensed gas stream; (2) said partially condensed gas stream divided into said first stream and said second stream; and (3) said second stream is separated thereby to provide said vapor stream and said at least one liquid stream.

3. The process according to claim 1 wherein (1) said first stream is combined with at least a portion of said at least one liquid stream to form a combined stream; (2) said combined stream is cooled to form a condensed combined stream; (3) said condensed combined stream is expanded to said lower pressure to form an expanded condensed combined stream that is thereafter supplied to said distillation column at said mid-column feed position; and (4) any remaining portion of said at least one liquid stream is expanded to said lower pressure to form said expanded liquid stream.

4. The process according to claim 1 wherein (1) said expanded condensed first portion is supplied at a mid-column feed position to a contacting and separating device that produces said distillation vapor stream and a bottom liquid stream, whereupon said bottom liquid stream is supplied to said distillation column at said top feed position and wherein said contacting and separating device comprises an absorption column containing a plurality of vertically spaced trays, one or more packed beds or a combination of trays and packing; (2) an overhead vapor stream is withdrawn from said upper region of said distillation column and is supplied to said contacting and separating device at a lower column feed position below said mid-column feed position; (3) said expanded condensed compressed recycle stream is supplied at a top feed position to said contacting and separating device; and (4) an overhead temperature of said contacting and separating device is at a temperature whereby portions of components in said less volatile fraction are recovered.

5. The process according to claim 4 wherein (1) said gas stream is cooled under pressure to form a partially condensed gas stream; (2) said partially condensed gas stream divided into said first stream and said second stream; and (3) said second stream is separated thereby to provide said vapor stream and said at least one liquid stream.

6. The process according to claim 4 wherein (1) said first stream is combined with at least a portion of said at least one liquid stream to form a combined stream; (2) said combined stream is cooled to form a condensed combined stream; (3) said condensed combined stream is expanded to said lower pressure to form an expanded condensed combined stream that is thereafter supplied to said distillation column at said top feed position; and (4) any remaining portion of said at least one liquid stream is expanded to said lower pressure to form said expanded liquid stream.

7. An apparatus for the separation of a gas stream containing methane, C2 components, C3 components, and heavier hydrocarbon components into a volatile residue gas fraction and a less volatile fraction containing a portion of said C2 components, C3 components, and heavier hydrocarbon components or said C3 components and heavier hydrocarbon components, in said apparatus there being (a) a first cooling means comprising a heat exchanger to cool said gas stream under pressure connected to provide a cooled stream under pressure; (b) a first expansion means comprising an expansion valve or a work expansion machine connected to receive at least a portion of said cooled stream under pressure and expand said at least a portion of said cooled stream to a lower pressure, whereby said stream is further cooled; and (c) a distillation column connected to receive said further cooled stream, said distillation column being adapted to separate said further cooled stream into said volatile residue gas fraction and said less volatile fraction; wherein said apparatus includes (1) a first dividing means comprising a piping tee prior to said first cooling means to divide said gas stream into first and second streams; (2) a heat exchange means comprising a heat exchanger connected to said first dividing means to receive said first stream and cool said first stream to form a condensed first stream; (3) said first expansion means connected to said heat exchange means, said first expansion means being adapted to receive said condensed first stream and expand said condensed first stream to said lower pressure to form an expanded condensed first stream, said first expansion means being further connected to said distillation column to supply said expanded condensed first stream to said distillation column at a mid-column feed position; (4) said first cooling means connected to said first dividing means to receive said second stream and cool said second stream under pressure to form a partially condensed second stream; (5) a separating means comprising a vessel to separate a two-phase into vapor and liquid connected to said first cooling means to receive said partially condensed second stream and separate said partially condensed second stream into a vapor stream and at least one liquid stream; (6) a second dividing means comprising a piping tee connected to said separating means to receive said vapor stream and divide said vapor stream into first and second portions; (7) said heat exchange means further connected to said second dividing means to receive said first portion and cool first portion to form a condensed first portion; (8) a second expansion means comprising an expansion valve connected to said heat exchange means to receive said condensed first portion and expand said condensed first portion to said lower pressure to form an expanded condensed first portion, said second expansion means being further connected to said distillation column to supply said expanded condensed first portion to said distillation column at an upper mid-column feed position above said mid-column feed position; (9) a third expansion means comprising an expansion valve being connected to said second dividing means to receive said second portion and expand said second portion to said lower pressure to form an expanded second portion, said third expansion means being further connected to said distillation column to supply said expanded second portion to said distillation column at a lower mid-column feed position below said mid-column feed position; (10) a fourth expansion means comprising an expansion valve connected to said separating means to receive at least a portion of said at least one liquid stream and expand said at least one liquid stream to said lower pressure to form an expanded liquid stream, said fourth expansion means being further connected to said distillation column to supply said expanded liquid stream to said distillation column at another lower mid-column feed position below said mid-column feed position; (11) an overhead stream line from a top of said distillation column to receive a distillation vapor stream from an upper region of said distillation column; (12) said heat exchange means further connected to said overhead stream line to receive said distillation vapor stream and heat said distillation vapor stream to form a heated distillation vapor stream, thereby to supply at least a portion of said cooling of elements (2) and (7); (13) a compressing means comprising a compressor connected to said heat exchange means to receive said heated distillation vapor stream and compress said heated distillation vapor stream to higher pressure to form a compressed heated distillation vapor stream; (14) a second cooling means comprising a heat exchanger connected to said compressing means to receive said compressed heated distillation vapor stream and cool aid compressed heated distillation vapor stream to form a cooled compressed heated distillation vapor stream; (15) a third dividing means comprising a piping tee connected to said second cooling means to receive said cooled compressed heated distillation vapor stream and divide said cooled compressed heated distillation vapor stream into said volatile residue gas fraction and a compressed recycle stream; (16) said heat exchange means further connected to said third dividing means to receive said compressed recycle stream and cool said compressed recycle stream to form a condensed compressed recycle stream, thereby to supply at least a portion of said heating of element (12); and (17) a fifth expansion means comprising an expansion valve or a work expansion machine connected to said heat exchange means to receive said condensed compressed recycle stream and expand condensed compressed recycle stream to said lower pressure to form an expanded condensed compressed recycle stream, said fifth expansion means being further connected to said distillation column to supply said expanded condensed compressed recycle stream to said distillation column at a top feed position.

8. The apparatus according to claim 7 wherein (1) said first cooling means is connected to receive said gas stream and cool said gas stream under pressure to form a partially condensed gas stream; (2) said first dividing means is connected to said first cooling means to receive said partially condensed gas stream and divide said partially condensed gas stream into said first stream and said second stream; and (3) said separating means is connected to said first dividing means to receive said second stream and separate said second stream into said vapor stream and said at least one liquid stream.

9. The apparatus according to claim 7 wherein (1) a combining means comprising a piping tee is connected to said first dividing means and said separating means to receive said first stream and at least a portion of said at least one liquid stream and form a combined stream; (2) said heat exchange means is connected to said combining means to receive said combined stream and cool said second stream to form a condensed combined stream; (3) said first expansion means is connected to said heat exchange means to receive said condensed combined stream and expand said condensed combined stream to said lower pressure to form an expanded condensed combined stream, said first expansion means being further connected to said distillation column to supply said expanded condensed combined stream to said distillation column at said mid-column feed position; and (4) said fourth expansion means is connected to said separating means to receive any remaining portion of said at least one liquid stream and expand said at least one liquid stream to said lower pressure to form said expanded liquid stream.

10. The apparatus according to claim 7 wherein (1) said second expansion means is connected to a contacting and separating means to supply said expanded condensed first portion to said contacting and separating means at a mid-column feed position, said contacting and separating means being adapted to produce said distillation vapor stream and a bottom liquid stream; (2) said distillation column is connected to receive said bottom liquid stream at said top feed position, said distillation column being adapted to separate said bottom liquid stream into an overhead vapor stream and said less volatile fraction; (3) said contacting and separating means is further connected to said distillation column to receive said overhead vapor stream at a lower column feed position below said mid-column feed position; and (4) said contacting and separating means is further connected to said fifth expansion means to receive said expanded condensed compressed recycle stream and supply said expanded condensed compressed recycle stream to said contacting and separating means at a top feed position.

11. The apparatus according to claim 10 wherein (1) said first cooling means is connected to receive said gas stream and cool said gas stream under pressure to form a partially condensed gas stream; (2) said first dividing means is connected to said first cooling means to receive said partially condensed gas stream and divide said partially condensed gas stream into said first stream and said second stream; and (3) said separating means is connected to said first dividing means to receive said second stream and separate said second stream into said vapor stream and said at least one liquid stream.

12. The apparatus according to claim 10 wherein (1) a combining means comprising a piping tee is connected to said first dividing means and said separating means to receive said first stream and at least a portion of said at least one liquid stream and form a combined stream; (2) said heat exchange means is connected to said combining means to receive said combined stream and cool said combined stream to form a condensed combined stream; (3) said first expansion means is connected to said heat exchange means to receive said condensed combined stream and expand said condensed combined stream to said lower pressure to form an expanded condensed combined stream, said first expansion means being further connected to said distillation column to supply said expanded condensed combined stream to said distillation column at said top feed position; and (4) said fourth expansion means is connected to said separating means to receive any remaining portion of said at least one liquid stream and expand said at least one liquid stream to said lower pressure to form said expanded liquid stream.

Description

(1) For a better understanding of the present invention, reference is made to the following examples and drawings. Referring to the drawings:

(2) FIG. 1 is a flow diagram of a prior art natural gas processing plant in accordance with U.S. Pat. No. 4,157,904 or 4,278,457;

(3) FIG. 2 is a flow diagram of a prior art natural gas processing plant adapted to operate in accordance with U.S. Pat. No. 5,568,737;

(4) FIG. 3 is a flow diagram of a natural gas processing plant in accordance with the present invention; and

(5) FIGS. 4 through 6 are flow diagrams illustrating alternative means of application of the present invention to a natural gas stream.

(6) In the following explanation of the above figures, tables are provided summarizing flow rates calculated for representative process conditions. In the tables appearing herein, the values for flow rates (in moles per hour) have been rounded to the nearest whole number for convenience. The total stream rates shown in the tables include all non-hydrocarbon components and hence are generally larger than the sum of the stream flow rates for the hydrocarbon components. Temperatures indicated are approximate values rounded to the nearest degree. It should also be noted that the process design calculations performed for the purpose of comparing the processes depicted in the figures are based on the assumption of no heat leak from (or to) the surroundings to (or from) the process. The quality of commercially available insulating materials makes this a very reasonable assumption and one that is typically made by those skilled in the art.

(7) For convenience, process parameters are reported in both the traditional British units and in the units of the Système International d'Unités (SI). The molar flow rates given in the tables may be interpreted as either pound moles per hour or kilogram moles per hour. The energy consumptions reported as horsepower (HP) and/or thousand British Thermal Units per hour (MBTU/Hr) correspond to the stated molar flow rates in pound moles per hour. The energy consumptions reported as kilowatts (kW) correspond to the stated molar flow rates in kilogram moles per hour.

DESCRIPTION OF THE PRIOR ART

(8) FIG. 1 is a process flow diagram showing the design of a processing plant to recover C.sub.2+ components from natural gas using prior art according to U.S. Pat. No. 4,157,904 or 4,278,457. In this simulation of the process, inlet gas enters the plant at 120° F. [49° C.] and 790 psia [5,445 kPa(a)] as stream 31. If the inlet gas contains a concentration of sulfur compounds which would prevent the product streams from meeting specifications, the sulfur compounds are removed by appropriate pretreatment of the feed gas (not illustrated). In addition, the feed stream is usually dehydrated to prevent hydrate (ice) formation under cryogenic conditions. Solid desiccant has typically been used for this purpose.

(9) The feed stream 31 is cooled in heat exchanger 10 by heat exchange with cool residue gas (stream 39a), pumped liquid product at 48° F. [9° C.] (stream 42a), demethanizer reboiler liquids at 21° F. [−6° C.] (stream 41), demethanizer side reboiler liquids at −42° F. [−41° C.] (stream 40), and propane refrigerant. Note that in all cases exchangers 10 and 12 are representative of either a multitude of individual heat exchangers or a single multi-pass heat exchanger, or any combination thereof. (The decision as to whether to use more than one heat exchanger for the indicated cooling services will depend on a number of factors including, but not limited to, inlet gas flow rate, heat exchanger size, stream temperatures, etc.) Stream 31a then enters separator 11 at −28° F. [−33° C.] and 765 psia [5,275 kPa(a)] where the vapor (stream 32) is separated from the condensed liquid (stream 33).

(10) The vapor (stream 32) from separator 11 is divided into two streams, 34 and 37. The liquid (stream 33) from separator 11 is optionally divided into two streams, 35 and 38. (If stream 35 contains any portion of the separator liquid, then the process of FIG. 1 is according to U.S. Pat. No. 4,157,904. Otherwise, the process of FIG. 1 is according to U.S. Pat. No. 4,278,457.) For the process illustrated in FIG. 1, stream 35 contains none of the total separator liquid. Stream 34, containing about 28% of the total separator vapor, passes through heat exchanger 12 in heat exchange relation with the cold residue gas (stream 39) where it is cooled to substantial condensation. The resulting substantially condensed stream 36a at −141° F. [−96° C.] is then flash expanded through expansion valve 13 to the operating pressure (approximately 203 psia [1,398 kPa(a)]) of fractionation tower 17. During expansion a portion of the stream is vaporized, resulting in cooling of the total stream. In the process illustrated in FIG. 1, the expanded stream 36b leaving expansion valve 13 reaches a temperature of −174° F. [−114° C.] and is supplied to separator section 17a in the upper region of fractionation tower 17. The liquids separated therein become the top feed to rectifying section 17b.

(11) The remaining 72% of the vapor from separator 11 (stream 37) enters a work expansion machine 14 in which mechanical energy is extracted from this portion of the high pressure feed. The machine 14 expands the vapor substantially isentropically to the tower operating pressure, with the work expansion cooling the expanded stream 37a to −115° F. [−82° C.]. The typical commercially available expanders are capable of recovering on the order of 80-85% of the work theoretically available in an ideal isentropic expansion. The work recovered is often used to drive a centrifugal compressor (such as item 15) that can be used to re-compress the residue gas (stream 39b), for example. The partially condensed expanded stream 37a is thereafter supplied as feed to fractionation tower 17 at an upper mid-column feed point. The remaining separator liquid in stream 38 (if any) is expanded to the operating pressure of fractionation tower 17 by expansion valve 16, cooling stream 38a to −72° F. [−58° C.] before it is supplied to fractionation tower 17 at a lower mid-column feed point.

(12) The demethanizer in tower 17 is a conventional distillation column containing a plurality of vertically spaced trays, one or more packed beds, or some combination of trays and packing. As is often the case in natural gas processing plants, the fractionation tower may consist of three sections. The upper section 17a is a separator wherein the partially vaporized top feed is divided into its respective vapor and liquid portions, and wherein the vapor rising from the intermediate rectifying or absorbing section 17b is combined with the vapor portion of the top feed to form the cold demethanizer overhead vapor (stream 39) which exits the top of the tower. The intermediate rectifying (absorbing) section 17b contains the trays and/or packing to provide the necessary contact between the vapor portions of the expanded streams 37a and 38a rising upward and cold liquid falling downward to condense and absorb the C.sub.2 components, C.sub.3 components, and heavier components. The lower demethanizing or stripping section 17c contains the trays and/or packing and provides the necessary contact between the liquids falling downward and the vapors rising upward. The demethanizing section 17c also includes reboilers (such as the reboiler and the side reboiler described previously and optional supplemental reboiler 18) which heat and vaporize a portion of the liquids flowing down the column to provide the stripping vapors which flow up the column to strip the liquid product, stream 42, of methane and lighter components.

(13) The liquid product stream 42 exits the bottom of the tower at 37° F. [3° C.], based on a typical specification of a methane concentration of 0.5% on a volume basis in the bottom product. The residue gas (demethanizer overhead vapor stream 39) passes countercurrently to the incoming feed gas in heat exchanger 12 where it is heated from −156° F. [−104° C.] to −57° F. [−49° C.] (stream 39a) and in heat exchanger 10 where it is heated to 110° F. [43° C.] (stream 39b). The residue gas is then re-compressed in two stages. The first stage is compressor 15 driven by expansion machine 14. The second stage is compressor 19 driven by a supplemental power source which compresses the residue gas (stream 39d) to sales line pressure. After cooling to 125° F. [52° C.] in discharge cooler 20, the residue gas product (stream 39e) flows to the sales gas pipeline at 1065 psia [7,341 kPa(a)], sufficient to meet line requirements (usually on the order of the inlet pressure).

(14) A summary of stream flow rates and energy consumption for the process illustrated in FIG. 1 is set forth in the following table:

(15) TABLE-US-00001 TABLE I (FIG. 1) Stream Flow Summary - Lb. Moles/Hr [kg moles/Hr] Stream Methane Ethane Propane Butanes+ Total 31 19,089 2,416 1,292 826 24,147 32 17,283 1,558 455 99 19,901 33/38 1,806 858 837 727 4,246 34/36 4,825 435 127 28 5,556 37 12,458 1,123 328 71 14,345 39 19,054 347 4 0 19,928 42 35 2,069 1,288 826 4,219 Recoveries* Ethane 85.65% Propane 99.68% Butanes+ 99.99% Power Residue Gas Compression 18,225 HP [29,962 kW] Refrigerant Compression 4,072 HP [6,694 kW] Total Compression 22,297 HP [36,656 kW] *(Based on un-rounded flow rates)

(16) FIG. 2 is a process flow diagram showing one means of improving the performance of the FIG. 1 process to recover more of the C.sub.2 components in the bottom liquid product. FIG. 1 can be adapted to use the process of U.S. Pat. No. 5,568,737 as shown in FIG. 2. The feed gas composition and conditions considered in the process presented in FIG. 2 are the same as those in FIG. 1. Accordingly, the FIG. 2 process can be compared with that of the FIG. 1 process. In the simulation of this process, as in the simulation for the process of FIG. 1, operating conditions were selected to maximize the recovery level for a given energy consumption.

(17) Most of the process conditions shown for the FIG. 2 process are much the same as the corresponding process conditions for the FIG. 1 process. The main difference is the addition of a rectification column 25 that uses a recycle stream from the residue gas as its top feed to recover additional C.sub.2 components and heavier components from fractionation tower 17 overhead vapor stream 39 supplied to rectification column 25 as its bottom feed.

(18) Rectified overhead vapor stream 152 leaves the upper region of rectification tower 25 at −156° F. [−105° C.] and is directed into heat exchanger 23 where it provides cooling to partially cooled recycle stream 151a and partially cooled stream 36a before the heated stream 152a at −70° F. [−57° C.] is divided into streams 156 and 157. Stream 156 flows to heat exchanger 22 where it is heated to 120° F. [49° C.] as it provides cooling to recycle stream 151, while stream 157 flows to heat exchanger 12 and heat exchanger 10 as described previously. The resulting warm streams 156a and 157b recombine to form stream 152b at 105° F. [40° C.], which is compressed and cooled as described previously to form stream 152e. Stream 152e is then divided to form recycle stream 151 and the residue gas product (stream 153).

(19) Recycle stream 151 is cooled to −151° F. [−102° C.] and substantially condensed in heat exchanger 22 and heat exchanger 23, then flash expanded through expansion valve 24 to the operating pressure (approximately 227 psia [1,563 kPa(a)]) of rectification column 25 (slightly lower than the operating pressure of fractionation tower 17). During expansion a portion of the stream is vaporized, resulting in cooling of the total stream. In the process illustrated in FIG. 2, the expanded stream 151c leaving expansion valve 24 is cooled to −175° F. [−115° C.] and supplied as the top feed to rectification column 25.

(20) Rectification column 25 is a conventional absorption column containing a plurality of vertically spaced trays, one or more packed beds, or some combination of trays and packing. As is often the case in natural gas processing plants, the rectification column may consist of two sections. The upper section is a separator wherein the partially vaporized top feed is divided into its respective vapor and liquid portions, and wherein the vapor rising from the lower rectification section is combined with the vapor portion of the top feed to form the rectified overhead vapor (stream 152) which exits the top of the column. The lower, rectifying section contains the trays and/or packing and provides the necessary contact between the liquids falling downward and the vapors rising upward so that the cold liquid reflux from stream 151c absorbs and condenses the C.sub.2 components, C.sub.3 components, and heavier components rising in the rectifying section of rectification column 25. The liquid (stream 154) leaving the bottom of rectification column 25 at −149° F. [−100° C.] is pumped to higher pressure by pump 26 and combined with flash expanded stream 36c, with the resulting stream 155 at −168° F. [−111° C.] supplied to fractionation tower 17 at its top feed point.

(21) A summary of stream flow rates and energy consumption for the process illustrated in FIG. 2 is set forth in the following table:

(22) TABLE-US-00002 TABLE II (FIG. 2) Stream Flow Summary - Lb. Moles/Hr [kg moles/Hr] Stream Methane Ethane Propane Butanes+ Total 31 19,089 2,416 1,292 826 24,147 32 17,516 1,642 503 113 20,282 33/38 1,573 774 789 713 3,865 34/36 4,611 432 132 30 5,339 37 12,905 1,210 371 83 14,943 39 19,273 453 5 0 20,256 151 1,157 19 0 0 1,208 152 20,210 339 0 0 21,105 156 1,314 22 0 0 1,372 157 18,896 317 0 0 19,733 154 220 133 5 0 359 155 4,831 565 137 30 5,698 153 19,053 320 0 0 19,897 42 36 2,096 1,292 826 4,250 Recoveries* Ethane 86.77% Propane 100.00% Butanes+ 100.00% Power Residue Gas Compression 18,198 HP [29,917 kW] Refrigerant Compression 4,028 HP [6,622 kW] Total Compression 22,226 HP [36,539 kW] *(Based on un-rounded flow rates)

(23) A comparison of Tables I and II shows that, compared to the FIG. 1 process, the FIG. 2 process improves ethane recovery from 85.65% to 86.77%, propane recovery from 99.68% to 100.00%, and butane+ recovery from 99.99% to 100.00%. Comparison of Tables I and II further shows that these increased product yields were achieved without using additional power.

DESCRIPTION OF THE INVENTION

(24) FIG. 3 illustrates a flow diagram of a process in accordance with the present invention. The feed gas composition and conditions considered in the process presented in FIG. 3 are the same as those in FIGS. 1 and 2. Accordingly, the FIG. 3 process can be compared with that of the FIGS. 1 and 2 processes to illustrate the advantages of the present invention.

(25) Most of the process conditions shown for the FIG. 3 process are much the same as the corresponding process conditions for the FIG. 2 process. The main differences are the disposition of flash expanded substantially condensed stream 34c, and the new top feed for fractionation column 17 formed from a portion of the feed gas (stream 162) and the pumped liquid (stream 154a) from rectification column 25. In the FIG. 3 process, feed gas stream 31 is divided into two streams, stream 161 and stream 162. Stream 161 is directed to heat exchanger 10 to be cooled as described previously, and enters separator 11 at −24° F. [−31° C.] and 759 psia [5,232 kPa(a)] to be separated into vapor stream 32 and liquid stream 33. Streams 32 and 33 are then processed much as before.

(26) However, partially cooled stream 34a at −44° F. [−42° C.] is further cooled to −159° F. [−106° C.] and substantially condensed in heat exchanger 23 before it is flash expanded through expansion valve 27 to the operating pressure (approximately 222 psia [1,531 kPa(a)]) of rectification column 25 (slightly below the operating pressure of fractionation tower 17). During expansion a portion of the stream may be vaporized, resulting in cooling of the total stream. In the process illustrated in FIG. 3, the expanded stream 34c leaving expansion valve 27 is cooled to −172° F. [−113° C.] and directed to a mid-column feed point on rectification column 25.

(27) The other portion of the feed gas (stream 162) is directed to heat exchanger 22 and heat exchanger 23 and is cooled to −159° F. [−106° C.] and substantially condensed (stream 163a). Stream 163a is then flash expanded through expansion valve 13 to slightly above the operating pressure (approximately 227 psia [1,565 kPa(a)]) of fractionation tower 17. During expansion a portion of stream 163b may be vaporized, resulting in cooling of the total stream to −168° F. [−111° C.]. Recycle stream 151 is likewise cooled to −159° F. [−106° C.] and substantially condensed in heat exchanger 22 and heat exchanger 23 and then flash expanded through expansion valve 24 to the operating pressure of rectification column 25. During expansion a portion of the stream may be vaporized, resulting in cooling of the total stream. In the process illustrated in FIG. 3, the expanded stream 151c leaving expansion valve 24 at −177° F. [−116° C.] is directed to a top column feed point on rectification column 25.

(28) Overhead vapor stream 39 at −130° F. [−90° C.] is withdrawn from an upper region of fractionation tower 17 and directed to the bottom column feed point of rectification column 25. Rectification column 25 is a conventional absorption column containing a plurality of vertically spaced trays, one or more packed beds, or some combination of trays and packing. As is often the case in natural gas processing plants, the rectification column may consist of two sections. The upper section is a separator wherein the partially vaporized top feed is divided into its respective vapor and liquid portions, and wherein the vapor rising from the lower rectification section is combined with the vapor portion of the top feed to form the rectified overhead vapor (stream 152) which exits the top of the column. The lower, rectifying section contains the trays and/or packing and provides the necessary contact between the liquids falling downward and the vapors rising upward so that the cold liquid reflux from streams 151c and 34c absorbs and condenses the C.sub.2 components, C.sub.3 components, and heavier components rising in the rectifying section of rectification column 25. The liquid (stream 154) leaving the bottom of rectification column 25 at −132° F. [−91° C.] is pumped to higher pressure by pump 26 and combined with flash expanded stream 163b, with the resulting stream 155 at −151° F. [−102° C.] supplied to fractionation tower 17 at its top feed point.

(29) Rectified overhead vapor stream 152 leaves the upper region of rectification tower 25 at −164° F. [−109° C.] and is directed into heat exchanger 23 where it provides cooling to partially cooled recycle stream 151a, the partially cooled portion of the feed gas (stream 163), and partially cooled stream 34a before the heated stream 152a at −44° F. [−42° C.] is divided into streams 156 and 157. Stream 156 flows to heat exchanger 22 where it is heated to 109° F. [43° C.] as it provides cooling to recycle stream 151 and the portion of the feed gas (stream 162), while stream 157 flows to heat exchanger 12 and heat exchanger 10 as described previously. The resulting warm streams 156a and 157b recombine to form stream 152b at 108° F. [42° C.], which is compressed and cooled as described previously to form stream 152e at 125° F. [52° C.] and 1065 psia [7,341 kPa(a)]. Stream 152e is then divided to form recycle stream 151 and the residue gas product (stream 153).

(30) A summary of stream flow rates and energy consumption for the process illustrated in FIG. 3 is set forth in the following table:

(31) TABLE-US-00003 TABLE III (FIG. 3) Stream Flow Summary - Lb. Moles/Hr [kg moles/Hr] Stream Methane Ethane Propane Butanes+ Total 31 19,089 2,416 1,292 826 24,147 161 17,333 2,194 1,173 750 21,925 162/163 1,756 222 119 76 2,222 32 15,882 1,482 451 101 18,378 33/38 1,451 712 722 649 3,547 34 3,131 292 89 20 3,624 37 12,751 1,190 362 81 14,754 39 16,743 832 13 1 18,024 151 1,164 11 0 0 1,208 152 20,216 195 0 0 20,968 156 14,920 144 0 0 15,474 157 5,296 51 0 0 5,494 154 822 940 102 21 1,888 155 2,578 1,162 221 97 4,110 153 19,052 184 0 0 19,760 42 37 2,232 1,292 826 4,387 Recoveries* Ethane 92.40% Propane 100.00% Butanes+ 100.00% Power Residue Gas Compression 18,190 HP [29,904 kW] Refrigerant Compression 4,049 HP [6,656 kW] Total Compression 22,239 HP [36,560 kW] *(Based on un-rounded flow rates)

(32) The magnitude of the performance increase of the present invention over that of the prior art is unexpectedly large. A comparison of Tables I and III shows that, compared to the FIG. 1 process, the FIG. 3 process improves ethane recovery from 85.65% to 92.40% (an increase of nearly 7 percentage points), propane recovery from 99.68% to 100.00%, and butane+ recovery from 99.99% to 100.00%. Comparison of Tables I and III further shows that these increased product yields were achieved without using additional power. In terms of the recovery efficiency (defined by the quantity of ethane recovered per unit of power), the present invention represents a very significant 8% improvement over the prior art of the FIG. 1 process.

(33) A comparison of Tables II and III shows that, compared to the FIG. 2 process, the FIG. 3 process improves ethane recovery from 86.77% to 92.40% (an increase of over 5 percentage points) and the propane and butane+ recoveries are the same (100.00%). Comparison of Tables II and III further shows that these increased product yields were achieved without using additional power. In terms of the recovery efficiency (defined by the quantity of ethane recovered per unit of power), the present invention represents a very significant 6% improvement over the prior art of the FIG. 2 process.

(34) The improvement in the recovery efficiency of the present invention over that of the prior art processes can be understood by examining the improvement in the rectification that the present invention provides compared to that provided for rectifying section 17b of the FIGS. 1 and 2 processes and rectification column 25 of the FIG. 2 process. Whereas the FIG. 1 process has a single reflux stream (stream 36b) for its rectifying section 17b in column 17, the present invention has three reflux streams (streams 151c and 34c for rectification column 25 and stream 155 for the rectifying section 17b in column 17). Not only is the total quantity of reflux greater for the present invention (by about 61%), its top reflux stream (stream 151c) is of much better quality since it is nearly pure methane, whereas the top reflux stream 36b for the FIG. 1 process contains more than 10% C.sub.2 components and heavier components.

(35) While the FIG. 2 process improves over the FIG. 1 process with its dual reflux streams (stream 151c for rectification column 25 and stream 155 for the rectifying section 17b in column 17), the total amount of reflux is 23% less than the triple reflux streams in the present invention. Further, the single reflux stream supplied to rectification column 25 for the FIG. 2 process is only 25% of the total reflux supplied to rectification column 25 for the present invention, making it less capable of rectifying overhead vapor stream 39 from column 17. Rectification column 25 of the present invention also has less of stream 39 to rectify in the first place, since it uses a portion of the feed gas (substantially condensed expanded stream 163b) to provide partial rectification of the tower vapors in rectifying section 17b of column 17 so that less rectification is needed in column 25. The combination of these factors results in an increase in the C.sub.2 component recovery for the present invention of nearly 7 percentage points over that of the FIG. 1 process and over 5 percentages points over that of the FIG. 2 process.

(36) One important advantage of the present invention is how easily it can be incorporated into an existing gas processing plant to achieve the superior performance described above. As shown in FIG. 3, only six connections (commonly referred to as “tie-ins”) to the existing plant are needed: for the feed gas split (stream 162), for the partially condensed stream (stream 34a), for the pumped liquids from rectification column 25 (stream 154a), for the fractionation column 17 overhead vapor (stream 39), for the heated residue gas (stream 156a), and for the compressed recycle gas (stream 151). The existing plant can continue to operate while the new heat exchangers 22 and 23, column 25, and pump 26 are installed near fractionation tower 17, with just a short plant shutdown when installation is complete to make the new tie-ins to these six existing lines. The plant can then be restarted, with all of the existing equipment remaining in service and operating exactly as before, except that the product recovery is now higher with no increase in compression power.

(37) Another advantage of the present invention is that there is less flow through the existing plant because part of the feed gas (stream 162) is split around the existing heat exchangers and separator, which results in less vapor/liquid traffic inside fractionation tower 17. This means there is a potential to process more feed gas and increase the plant revenue without debottlenecking the existing equipment if there is spare compression power available for the higher feed gas throughput.

OTHER EMBODIMENTS

(38) The present invention can also be applied in a new plant as shown in FIGS. 4 and 6. Depending on the quantity of heavier hydrocarbons in the feed gas and the feed gas pressure, the cooled feed stream 161a (FIG. 4) or 31a (FIG. 6) leaving heat exchanger 10 may not contain any liquid (because it is above its dewpoint, or because it is above its cricondenbar). In such cases, separator 11 shown in FIGS. 4 and 6 is not required.

(39) In accordance with the present invention, the splitting of the feed gas may be accomplished in several ways. In the processes of FIGS. 3 and 4, the splitting of the feed gas occurs before any cooling of the feed gas. In such cases, cooling and substantial condensation of one portion of the feed gas in multiple heat exchangers may be favored in some circumstances, such as heat exchangers 22 and 23 shown in FIG. 3 or heat exchangers 22 and 12 shown in FIG. 4. The feed gas may also be split, however, following cooling (but prior to separation of any liquids which may have been formed) as shown in FIGS. 5 and 6.

(40) The high pressure liquid (stream 33 in FIGS. 3 and 4) need not be expanded and fed to a mid-column feed point on the distillation column. Instead, all or a portion of it may be combined with the portion of the cooled feed gas (stream 162a) leaving heat exchanger 22 in FIGS. 3 and 4. (This is shown by the dashed stream 35 in FIGS. 3 and 4.) Any remaining portion of the liquid (stream 38 in FIGS. 3 and 4) may be expanded through an appropriate expansion device, such as expansion valve 16 or an expansion machine, and fed to a mid-column feed point on the distillation column (stream 38a). Stream 38 may also be used for inlet gas cooling or other heat exchange service before or after the expansion step prior to flowing to the demethanizer.

(41) As described earlier, a portion of the feed gas (stream 162) and a portion of the separator vapor (stream 34) are substantially condensed and the resulting condensate used to absorb valuable C.sub.2 components, C.sub.3 components, and heavier components from the vapors rising through rectifying section 17b of demethanizer 17 (FIGS. 4 and 6), or through rectification column 25 and rectifying section 17b of column 17 (FIGS. 3 and 5). However, the present invention is not limited to this embodiment. It may be advantageous, for instance, to treat only a portion of these vapors in this manner, or to use only a portion of the condensate as an absorbent, in cases where other design considerations indicate portions of the vapors or the condensate should bypass rectifying section 17b of demethanizer 17 (FIGS. 4 and 6), or rectification column 25 and/or rectifying section 17b of column 17 (FIGS. 3 and 5).

(42) Feed gas conditions, plant size, available equipment, or other factors may indicate that elimination of work expansion machine 14, or replacement with an alternate expansion device (such as an expansion valve), is feasible. Although individual stream expansion is depicted in particular expansion devices, alternative expansion means may be employed where appropriate. For example, conditions may warrant work expansion of the substantially condensed portion of the separator vapor (stream 34b in FIGS. 3 and 5 and stream 34a in FIGS. 4 and 6) or the substantially condensed portion of the feed stream (stream 163a in FIGS. 3 and 4 and stream 162a in FIGS. 5 and 6).

(43) In accordance with the present invention, the use of external refrigeration to supplement the cooling available to the inlet gas, separator vapor, and/or recycle stream from other process streams may be employed, particularly in the case of a rich inlet gas. The use and distribution of separator liquids and demethanizer side draw liquids for process heat exchange, and the particular arrangement of heat exchangers for inlet gas and separator vapor cooling must be evaluated for each particular application, as well as the choice of process streams for specific heat exchange services.

(44) It will also be recognized that the relative amount of feed found in each branch of the split vapor feeds will depend on several factors, including gas pressure, feed gas composition, the amount of heat which can economically be extracted from the feed, and the quantity of horsepower available. More feed to the top of the column may increase recovery while decreasing power recovered from the expander thereby increasing the recompression horsepower requirements. Increasing feed lower in the column reduces the horsepower consumption but may also reduce product recovery. The relative locations of the mid-column feeds may vary depending on inlet composition or other factors such as desired recovery levels and amount of liquid formed during inlet gas cooling. Moreover, two or more of the feed streams, or portions thereof, may be combined depending on the relative temperatures and quantities of individual streams, and the combined stream then fed to a mid-column feed position.

(45) The present invention provides improved recovery of C.sub.2 components, C.sub.3 components, and heavier hydrocarbon components or of C.sub.3 components and heavier hydrocarbon components per amount of utility consumption required to operate the process. An improvement in utility consumption required for operating the process may appear in the form of reduced power requirements for compression or re-compression, reduced power requirements for external refrigeration, reduced energy requirements for supplemental heating, or a combination thereof.

(46) While there have been described what are believed to be preferred embodiments of the invention, those skilled in the art will recognize that other and further modifications may be made thereto, e.g. to adapt the invention to various conditions, types of feed, or other requirements without departing from the spirit of the present invention as defined by the following claims.