Temperature controlled method to liquefy gas and a production plant using the method

Abstract

A method for liquefying gas involving pre-treating the gas stream in a pre-treater to remove impurities, and then passing the gas stream through a first flow path of a first heat exchanger to lower a temperature of the gas stream. The gas stream is then passed through the gas expansion turbine to lower a pressure of the gas stream and further decrease the temperature of the gas stream. The gas stream is then passed into a primary separator to separate the gas stream into a liquid stream and a cold gas stream. The liquid stream is collected. Selected quantities of the cold gas stream are passed through a second flow path of the first heat exchanger whereby a heat exchange takes place to cool the gas stream flowing through the first flow path to maintain the temperature of the gas stream entering the gas expansion turbine at a temperature which promotes the production of liquids.

Claims

1. A method for liquefying gas, comprising: obtaining a gas stream from a transmission pipeline at a pipeline pressure; pre-treating the gas stream in a pre-treater to remove impurities and produce a pre-treated gas stream; passing the pre-treated gas stream through a first flow path of a first heat exchanger to lower a temperature of the pre-treated gas stream to produce a cooled gas stream; passing the cooled gas stream from the first heat exchanger through a gas expansion turbine to produce an expanded gas stream by lowering a pressure of the cooled gas stream to about atmospheric pressure and further decrease the temperature of the cooled gas stream; passing the expanded gas stream into a primary separator to separate the expanded gas stream into Liquid Natural Gas (LNG) and a cold gas stream; collecting the LNG; passing selective quantities of the cold gas stream through a second flow path of the first heat exchanger whereby a heat exchange takes place in the first heat exchanger to cool the pre-treated gas stream flowing through the first flow path to maintain the temperature of the cooled gas stream entering the gas expansion turbine at a temperature which promotes the production of liquids; mixing a slip stream of the collected LNG into the cold gas stream via a mixer that is positioned downstream of the first heat exchanger and upstream of the gas expansion turbine, the slip stream causing natural gas liquids (NGLs) in the cold gas stream to condense to produce a mixed phase stream; passing the mixed phase stream through a preliminary separator positioned downstream of the mixer and upstream of the gas expansion turbine to separate the condensed NGLs from the mixed phase stream; and directing the remaining mixed phase stream to the gas expansion turbine.

2. The method of claim 1, further comprising the step of compressing a portion of the cold gas stream to the pipeline pressure and returning the compressed cold gas stream to the transmission pipeline downstream.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) These and other features of the invention will become more apparent from the following description in which reference is made to the appended drawings, the drawings are for the purpose of illustration only and are not intended to in any way limit the scope of the invention to the particular embodiment or embodiments shown, wherein:

(2) FIG. 1 is a schematic diagram of a facility equipped with a gas pre-treatment, an heat exchanger, an expander and a compressor to produce LNG.

(3) FIG. 2 is a schematic diagram of a facility equipped with an alternate cooling medium for the compression of the recycled vapour fraction.

(4) FIG. 3 is a schematic diagram of a facility equipped with the ability to recover natural gas liquids (NGLs).

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

(5) The method will now be described with reference to FIG. 1.

(6) As set forth above, this method was developed with a view to liquefying natural gas to form Liquid Natural Gas (LNG). The description of application of the method to LNG should, therefore, be considered as an example.

(7) Referring to FIG. 1, a pressurized pipeline natural gas stream 1 provides natural gas to users through line 29, valve 30 to flow distribution 37. A natural gas stream 2 is routed through flow control valve 3. The controlled flow enters the gas pre-treatment unit 5 through line 4. Pre-treatment is to remove contaminants and may not be required if the gas used is of sufficient quality. The pre-treated gas exits through line 6 and is mixed with recycled gas stream 25 through valve 26. The mixed gas stream 7 enters heat exchanger 8 where it is pre-cooled. The pressurized pre-cooled gas stream 9 enters expander 10 where the pressure is dropped resulting in a substantial temperature drop. The nearly isentropic expansion also produces torque and therefore shaft power that is converted into electricity through generator 11. The expanded gas stream 12 enters LNG receiver 13 where the liquid and vapour fractions are separated. The vapour stream 17 is routed through heat exchanger 8 to pre-cool inlet gas stream 7. The now warmed gas stream 18 enters compressor 20 through line 19 for re-compression. The compressor 20 shaft power is provided by a gas engine 22 which receives its fuel from gas line 21. The compressed recycled gas stream 23 is cooled in heat exchanger 24 before mixing it with inlet feed gas stream 6 through line 25. To prevent a buildup of nitrogen in the recycle gas stream 25, a bleeding gas stream 27 is routed to gas transmission line 29 through valve 28. The cooling of compressed recycled gas stream 23 is provided by a once through heat exchange from gas transmission line 29. The required gas coolant is routed through valve 31 and line 32 into heat exchanger 24 and the once through flow is returned to gas transmission line 29 through line 34 and valve 33. The LNG receiver 13 accumulates the LNG produced. LNG exits receiver 13 through stream 14 to supply LNG product pump 15, where it is pumped to storage through line 16.

(8) A main feature of this invention is the simplicity of the process which eliminates the use of external refrigeration systems. Another feature of the invention is the flexibility of the process to meet various operating conditions since the ratio of LNG production is proportional to the cold vapour stream generated and recycled. The invention also provides for a significant savings in energy when compared to other processes since it uses its recycled vapour stream as the coolant medium, the process produces its own refrigeration stream. The proposed invention can be used in any LNG production plant size.

(9) Referring to FIG. 2, the main difference from FIG. 1 is in the heat exchanger to cool recycle stream 23. In FIG. 2, the heat exchanger 50 is an air cooling heat exchanger where ambient air is used to cool stream 23. This process orientation provides an alternative method to produce LNG at albeit less efficient than when using heat exchanger 24 as shown in FIG. 1. A pressurized pipeline natural gas stream 1 provides natural gas to users through line 29, valve 30 to flow distribution 37. A natural gas stream 2 is routed through flow control valve 3, and enters the gas pre-treatment unit 5 through line 4. The pre-treated gas exits through line 6 and is mixed with recycle gas stream 25 through valve 26. The mixed gas stream 7 enters heat exchanger 8 where it is pre-cooled. The pressurized pre-cooled gas stream 9 enters expander 10 where the pressure is dropped resulting in a substantial temperature drop. The nearly isentropic expansion also produces torque and therefore shaft power that is converted into electricity through generator 11. The expanded gas stream 12 enters LNG receiver 13 where the liquid and vapour fractions are separated. The vapour stream 17 is routed through heat exchanger 8 to pre-cool inlet gas stream 7. The now warmed gas stream 18 enters compressor 20 through line 19 for re-compression. The compressor 20 shaft power is provided by a gas engine 22 which receives its fuel from gas line 21. The compressed recycled gas stream 23 is cooled in heat exchanger 51 before mixing it with inlet feed gas stream 6 through line 25. To prevent a buildup of nitrogen in the recycle gas stream 25, a bleeding gas stream 27 is routed to gas transmission line 29 through valve 28. The cooling of compressed recycled gas stream 23 is provided by an air cooling heat exchanger 51. The LNG receiver 13 accumulates the LNG produced. LNG exits receiver 13 through stream 14 to supply LNG product pump 15, where it is pumped to storage through line 16.

(10) Referring to FIG. 3, the main difference from FIGS. 1 and 2 is the recovery of natural gas liquids before expansion. This is achieved by circulating a portion of the generated liquid natural gas (LNG), stream 42 and mixing it in 43 with the pre-cooled gas stream 51 to meet the temperature required to condense the heavier fractions present in the natural gas stream such as; butane, propane and ethane. This process orientation provides an alternative method to produce both LNG and NGLs. A pressurized pipeline natural gas stream 1 provides natural gas to users through line 29, valve 30 to gas flow transmission line 37. A natural gas stream 2 is routed through flow control valve 3, and enters the gas pre-treatment unit 5 through line 4. The pre-treated gas exits through line 6 and is mixed with recycle gas stream 25 through valve 26, the mixed gas stream 7 enters heat exchanger 8 where it is pre-cooled. The pressurized pre-cooled gas stream 43 enters mixer 44, a LNG stream 42 is also added to mixer 44. The addition of LNG stream to mixer 44 is controlled by temperature control valve 41. The mixed stream 45, enters separator 46 where the NGLs are separated and accumulated. The NGLs exit separator 46 through line 47 to NGL pump 49 and pumped to storage through line 50. The pressurized, pre-cooled and de-liquified gas stream 9 enters expander 10 where the pressure is dropped resulting in a substantial temperature drop. The nearly isentropic expansion also produces torque and therefore shaft power that is converted into electricity through generator 11. The expanded gas stream 12 enters LNG receiver 13 where the liquid and vapour fractions are separated. The vapour stream 17 is routed through heat exchanger 8 to pre-cool inlet gas stream 7. The now warmed gas stream 18 enters compressor 20 through line 19 for re-compression. The compressor 20 shaft power is provided by a gas engine 22 which receives its fuel from gas line 21. The compressed recycled gas stream 23 is cooled in heat exchanger 24 before mixing it with inlet feed gas stream 6 through line 25 and valve 26. To prevent a buildup of nitrogen in the recycle gas stream 25, a bleeding gas stream 27 is routed to gas transmission line 29 through valve 28.

(11) The cooling of compressed recycled gas stream 23 is provided by a once through heat exchange from gas transmission line 29. The required gas coolant is routed through valve 31 and line 32 into heat exchanger 24 and the once through flow is returned to gas transmission line 29 through line 34 and valve 33.
The LNG receiver 13 accumulates the LNG produced. LNG exits receiver 13 through stream 14 to supply LNG product pump 15, where it is pumped to storage through line 16. A portion of the produced LNG is routed through line 38 to high pressure LNG pump 39. The pressurized LNG liquid stream is controlled by temperature valve 41 to a pre-set temperature through temperature transmitter 47. The controlled LNG stream 42 enters mixer 44 to cool and condense the desired natural gas liquids.
The proposed invention addresses both large and small plants in which process simplicity and ease of operation are the main components. The invention eliminates the need for refrigeration cycle plants and the use of proprietary mixed refrigerants. By simplifying the process, it reduces capital, maintenance, and operations costs.
In the preferred method, natural gas is first pre-cooled with produced cold vapor then expanded through a gas expander. The gas expander produces electricity. The expanded gas produces a vapour and a liquid stream. The vapour stream is recycled by first pre-cooling the feed gas to the expander and then recompressed, cooled and recycled. A portion of the produced LNG provides the cold energy required as a recycle stream to cool and liquefy the pre-treated natural gas stream to recover desired natural gas liquids. The proposed invention eliminates the practice and use of mixed refrigerant cycles resulting in lower capital and operating costs. The process is applicable to any LNG plant size.

VARIATIONS

(12) It should be noted that the motive force for the compressor can be provided by an electric motor versus a gas driven engine as proposed. Moreover, the compressed vapour stream can be discharged into gas transmission line 29 rather than recycled as proposed.

(13) In this patent document, the word comprising is used in its non-limiting sense to mean that items following the word are included, but items not specifically mentioned are not excluded. A reference to an element by the indefinite article a does not exclude the possibility that more than one of the element is present, unless the context clearly requires that there be one and only one of the elements.

(14) The scope of the claims should not be limited by the preferred embodiments set forth in the examples, but should be given a broad purposive interpretation consistent with the description as a whole.