SYSTEM FOR TREATING AND COOLING A HYDROCARBON STREAM

Abstract

The present invention relates to a system for treating and cooling a hydrocarbon stream, comprising a gas treatment stage comprising a pre-cooler to cool at least part of the hydrocarbon feed against cooling water, a first cooling stage comprising one or more first water coolers, a second cooling stage comprising one or more second water coolers. The system comprises a cooling water unit arranged to receive a stream of cooling water and supply a first part of the stream of cooling water to a chilling unit to obtain a stream of chilled cooling water and pass the stream of chilled cooling water to a selection of the at least one pre-cooler, the one or more first water coolers and the one or more second water coolers.

Claims

1. A system for treating and cooling a hydrocarbon stream, comprising: a gas treatment stage to receive the hydrocarbon stream and treat the hydrocarbon stream to generate a treated hydrocarbon stream, wherein the gas treatment stage comprises a pre-cooler to cool at least part of the hydrocarbon feed against cooling water, a first cooling stage to receive the treated hydrocarbon stream and cool the treated hydrocarbon stream against a first refrigerant to generate a cooled hydrocarbon stream, the first cooling stage comprising one or more first water coolers to cool the first refrigerant against cooling water, a second cooling stage to receive at least part of the cooled hydrocarbon stream and cool at least part of the cooled hydrocarbon stream against a second refrigerant to generate a further cooled hydrocarbon stream, the second cooling stage comprising one or more second water coolers to cool the second refrigerant against cooling water, wherein the system comprises a cooling water unit being in fluid communication with the at least one pre-cooler, the one or more first water coolers and the one or more second water coolers, wherein the cooling water unit is arranged to receive a stream of cooling water and supply a first part of the stream of cooling water to a chilling unit to obtain a stream of chilled cooling water and pass the stream of chilled cooling water to a selection of the at least one pre-cooler, the one or more first water coolers and the one or more second water coolers, and supply a second part of the stream of cooling water to a remainder of the at least one pre-cooler, the one or more first water coolers and the one or more second water coolers, without passing through any cooler, chiller or heat exchanger.

2. The system according to claim 1, wherein the chilling unit is a mechanical chiller.

3. The system according claim 1, wherein the chilling unit is arranged to receive the first part of the stream of cooling water at a feed temperature and to chill the first part of the stream of cooling water to a chilled temperature below the feed temperature.

4. The system according to claim 1, wherein the chilling unit is arranged to receive the first part of the stream of cooling water at a feed temperature to chill the first part of the stream of cooling water towards but not below a predetermined temperature.

5. The system according to claim 4, comprising a by-pass of the chiller unit for the first part of the stream of cooling water, wherein the system is arranged to pass the first part of the stream of cooling water through the by-pass in case the feed temperature is equal to or less than the predetermined temperature.

6. The system according to claim 4, wherein the system is arranged to switch of the chilling unit in case the feed temperature is equal or less than the predetermined temperature.

7. The system according to claim 1, wherein the first water coolers comprise one or more condensers, positioned downstream of a first refrigerant compressor stage arranged to receive and cool a compressed first refrigerant stream discharged by the first refrigerant compressor stage, one or more sub-coolers positioned downstream of the one or more condensors arranged to receive and cool at least part of the first refrigerant stream discharged by the one or more condensers, wherein the second water coolers comprise one or more after-coolers positioned downstream of a second refrigerant compressor stage arranged to receive and cool a compressed second refrigerant stream discharged by the second refrigerant compressor stage, one or more inter-coolers being in fluid communication with the compressor stage to receive a partially compressed second refrigerant stream from the second refrigerant compressor stage and pass an intercooled second refrigerant stream to the second refrigerant compressor stage for further compression, wherein the selection comprises the pre-cooler, the one or more sub-coolers and the one or more after-coolers.

8. The system according to claim 7, wherein the selection further comprises the one or more inter-coolers.

9. The system according to claim 7, wherein the selection further comprises the one or more condensers.

10. The method for treating and cooling a hydrocarbon stream comprising: receiving the hydrocarbon stream, treating the hydrocarbon stream to generate a treated hydrocarbon stream, wherein treating comprises pre-cooling the hydrocarbon feed stream in a pre-cooler against cooling water, cooling the treated hydrocarbon stream against a first refrigerant to generate a cooled hydrocarbon stream, wherein the first refrigerant is cooled in one or more first water coolers against cooling water, further cooling at least part of the cooled hydrocarbon stream against a second refrigerant to generate a further cooled hydrocarbon stream, wherein the second refrigerant is cooled in one or more second water coolers against cooling water, wherein the method further comprises receiving a stream of cooling water, splitting the stream of cooling water in a first part and a second part, passing the first part of the stream of cooling water to a chilling unit to obtain a stream of chilled cooling water, passing the stream of chilled cooling water to a selection of the at least one pre-cooler, the one or more first water coolers and the one or more second water coolers, passing the second part of the stream of cooling water to a remainder of the at least one pre-cooler, the one or more first water coolers and the one or more second water coolers, without passing through any cooler, chiller or heat exchanger.

11. The method according to claim 10, comprising: obtaining an indication of the temperature of the stream of chilled cooling water, controlling a working duty of the chilling unit to chill the first part of the stream of cooling water towards but not below a predetermined temperature.

12. The method according to claim 10, wherein the first water coolers comprise: one or more condensers, positioned downstream of a first refrigerant compressor stage arranged to receive and cool a compressed first refrigerant stream discharged by the first refrigerant compressor stage, one or more sub-coolers positioned downstream of the one or more condensers arranged to receive and cool at least part of the first refrigerant stream discharged by the one or more condensers, wherein the second water coolers comprise: one or more after-coolers positioned downstream of a second refrigerant compressor stage arranged to receive and cool a compressed second refrigerant stream discharged by the second refrigerant compressor stage, one or more inter-coolers being in fluid communication with the compressor stage to receive a partially compressed second refrigerant stream from the second refrigerant compressor stage and pass an intercooled second refrigerant stream to the second refrigerant compressor stage for further compression, wherein the selection comprises the pre-cooler, the one or more sub-coolers and the one or more after-coolers.

13. The method according to claim 12, wherein the selection further comprises the one or more inter-coolers.

14. The method according to claim 12, wherein the selection further comprises the one or more condensers.

Description

SHORT DESCRIPTION OF THE FIGURES

[0090] The invention will be further illustrated hereinafter, using examples and with reference to the drawing in which;

[0091] FIGS. 1, 2, 3 and 4 schematically show different embodiments.

[0092] In these figures, same reference numbers will be used to refer to same or similar parts. Furthermore, a single reference number will be used to identify a conduit or line as well as the stream conveyed by that line.

DETAILED DESCRIPTION

[0093] The embodiments provide a method and system in which a first part of the cooling water that is received is chilled to a lower temperature before being passed on to the gas treatment stage, first cooling stage and/or second cooling stage, while a second part of the cooling water is not chilled.

[0094] The cooling water is received at a feed temperature that depends on the ambient conditions.

[0095] For instance, the stream of cooling water may be received from a water tower. The water tower is arranged to cool warmed cooling water received back from the gas treatment stage, first cooling stage and/or second cooling stage against ambient, e.g. against ambient air. The resulting stream of cooling water is passed back to the gas treatment stage, first cooling stage and/or second cooling stage at a feed temperature depending on the ambient temperature, e.g. the ambient air temperature.

[0096] According to an other example, the stream of cooling water may be received from a water intake riser, in which case the feed temperature of the stream of cooling water depends on the temperature of the sea water.

[0097] By chilling a first part of the cooling water, the gas treatment stage, first cooling stage and/or second cooling stage will not be less influenced by changing ambient conditions and will be able to function in a more optimal manner.

[0098] FIG. 1 schematically depicts a system for treating and cooling a hydrocarbon stream.

[0099] FIG. 1 shows a gas treatment stage 10 arranged to receive a hydrocarbon stream 1. The gas treatment stage 10 comprises a number of gas treatment units, e.g. an acid gas removal unit 11, a dehydration unit 12, a mercury removal unit 13. The gas treatment stage 10 further comprises a pre-cooler 14 to cool at least part of the hydrocarbon feed 10 against cooling water 404 as will be described in more detail below.

[0100] The pre-cooler 14 is preferably positioned downstream (with respect to hydrocarbon stream 1) of the mercury removal unit 13 and upstream of the first cooling stage 100 (described below).

[0101] The pre-cooler 14 is shown as part of the gas treatment stage. However, it is preferably positioned directly upstream of the first heat exchanger 110 comprised by the first cooling stage 100 described in more detail below. The term directly upstream is used here to indicate that there are no further cooling, heating, separation devices in between the pre-cooler and the first heat exchanger 110. The pre-cooler 14 may also be considered to be part of the first cooling stage 100.

[0102] The gas treatment stage 10 is arranged to discharge a treated hydrocarbon stream 20.

[0103] FIG. 1 further shows a first cooling stage 100. The first cooling stage comprises a first heat exchanger 110 in which the treated hydrocarbon stream 20 is allowed to exchange heat against a first refrigerant creating a cooled hydrocarbon stream 30.

[0104] The first refrigerant may be a mixed refrigerant or may mainly comprise a single component, such as propane.

[0105] It will be understood that the first cooling stage 100 may comprise more than one first heat exchanger 110, where the more than one first heat exchangers 110 may be positioned in series and/or parallel with respect to each other. FIG. 1 only shows one for reasons of clarity.

[0106] The first cooling stage 100 further comprises a first refrigerant loop through which in use the first refrigerant is cycled. The first refrigerant loop comprises at least one first refrigerant compressor stage 121, which is depicted as comprising a single compressor. However, it will be understood that more than one compressor may be present, the more than one compressors may be arranged parallel and/or in series with respect to each other.

[0107] One or more, preferably all, of the compressors comprised by the first refrigerant compressor stage 121 may comprise watercooled desuperheaters 1210. The desuperheaters 1210 are considered part of the first refrigerant compressor stage 121.

[0108] Downstream of the first refrigerant compressor stage 121 are one or more condensors 122 arranged to receive and cool a compressed first refrigerant stream 131 discharged by the first refrigerant compressor stage 121. Downstream of the one or more condensors 122 are one or more sub-coolers 123, arranged to receive and cool at least part of the first refrigerant stream 132 discharged by the one or more condensors 122.

[0109] The condensors 122 discharge a condensed refrigerant stream 133 which is passed to an expansion device 124, optionally via the one or more first heat exchangers 100 as depicted. The expansion device 124 genates an expanded first refrigerant stream 134 which is passed to the one or more first heat exchangers 100 to cool the treated hydrocarbon stream 20. A resulting warmed first refrigerant stream 135 is collected from the one or more first heat exchangers 100 and passed back to the first refrigerant compressor stage 121.

[0110] The cooled hydrocarbon stream 30 obtained from the first cooling stage 100 is at least partially passed to the second cooling stage 200 for further cooling.

[0111] The second cooling stage 200 comprises a second heat exchanger 210 in which the cooled hydrocarbon stream 30 is allowed to exchange heat against a second refrigerant creating a a further cooled hydrocarbon stream 40. This further cooled hydrocarbon stream 40 may be (partially) liquefied and passed to a further cooling stage, an end-flash unit and/or a LNG storage tank (not shown).

[0112] The second refrigerant may be a mixed refrigerant.

[0113] The second heat exchanger 210 is usually referred to aqs a main cryogenic heat exchanger. It will be understood that the second cooling stage 200 may comprise more than one second heat exchanger 210, where the more than one second heat exchangers 110 may be positioned in series and/or parallel with respect to each other. FIG. 1 only shows one for reasons of clarity.

[0114] The second cooling stage 200 further comprises a second refrigerant loop through which in use the second refrigerant is cycled. The second refrigerant loop comprises a at least one second refrigerant compressor stage 221, which is depicted as comprising a single compressor. However, it will be understood that more than one compressor may be present, the more than one compressors may be arranged parallel and/or in series with respect to each other. Downstream of the second refrigerant compressor stage 221 are one or more after-coolers 222 arranged to receive and cool a compressed second refrigerant stream 231 discharged by the second refrigerant compressor stage 221. The after-coolers 222 discharge an after-cooled second refrigerant stream 232 which is further passed to and cooled by the one or more first heat exchangers 110.

[0115] The one or more first heat exchangers 110 discharge a partially condensed second refrigerant stream 233 which is passed on to a separator 234. The separator 234 generates a light gaseous stream 235 and a heavy liquid stream 236, which are both in parallel cooled by the second heat exchanger 210 and expanded by expansion devices 237, 238 respectively. The thereby obtained expanded heavy refrigerant stream 239 and heavy refrigerant stream 240 are passed to the second heat exchangers 210 to cool the cooled hydrocarbon stream 30.

[0116] A resulting warmed second refrigerant stream 241 is collected from the one or more second heat exchangers 210 and passed back to the second refrigerant compressor stage 221.

[0117] The second cooling stage 200 may further comprise one or more intercoolers 251 being in fluid communication with the second compressor stage 221 to receive a partially compressed second refrigerant stream 250 from the second refrigerant compressor stage 221 and pass an intercooled second refrigerant stream 252 to the second refrigerant compressor stage 221 for further compression.

[0118] So, the system as described comprises [0119] a pre-cooler 14 being part of the gas treatment stage 10, [0120] one or more first water coolers being part of the first cooling stage 100, such as the one or more condensors 122 and one or more sub-coolers 123 [0121] one or more second water coolers being part of the second cooling stage 200, such as the one or more after-coolers 222 and one or more intercoolers 251 of the second cooling stage 200,

[0122] which may all be in fluid communication with a cooling water unit 400 to receive cooling water and discharge warmed cooling water back to the water unit 400 or back to the ambient.

[0123] The cooling water unit 400 may be a water tower, but may also be a water intake system, such as a water intake riser system.

[0124] The cooling water unit 400 may be arranged to provide a stream of cooling water 401 which is split in a first and second part 402, 403. It will be understood that alternative embodiments may be conceived which result in a first and second part of cooling water. Also, the first and second part of cooling water 402, 403 are not necessarily conveyed in on conduit as shown schematically, but may also be conveyed in two or more conduits in parallel.

[0125] The system comprises a chilling unit 411 which is arranged to receive the first part of the stream of cooling water 402 and discharge a stream of chilled cooling water 404.

[0126] The chilling unit 411 may be any kind of chilling unit, but preferably is a mechanical chiller, as already described above.

[0127] The chilling unit 411 is in fluid communication with a selection of the at least one pre-cooler 14, the one or more first water coolers (122, 123) and the one or more second water coolers (251, 222) to supply them with chilled cooling water, while a remainder of the at least one pre-cooler 14, the one or more first water coolers and the one or more second water coolers is fed with non-chilled cooling water.

[0128] FIG. 1 depicts an embodiment in which the selection comprises the pre-cooler 14, the one or more sub-coolers 123 and the one or more after-coolers 222 and the remainder comprises the one or more condensors 122 of the first cooling stage 100 and the one or more intercoolers 251 of the second cooling stage 200.

[0129] FIG. 2 depicts an embodiment in which the selection further comprises the one or more inter-coolers 251 and the remainder does not comprise the one or more inter-coolers 251 but does comprise the one or more condensors 122 of the first cooling stage 100.

[0130] FIG. 3 depicts an embodiment in which the selection further comprises the one or more condensors 122 of the first cooling stage and the remainder does not comprise the one or more condensors 122 but does comprise the one or more inter-coolers 251 the second cooling stage 200.

[0131] FIG. 4 depicts an embodiment in which the selection comprises the one or more condensors 122 of the first cooling stage 100 and the one or more inter-coolers 251 of the second cooling stage 200.

[0132] It will be understood that additional water cooled heat exchangers may be present.

[0133] In all embodiments shown and described, the remainder of the at least one pre-cooler 14, the one or more first water coolers and the one or more second water coolers may further comprise one or more of all additional water cooled heat exchangers that are present in the system and are not fed with chilled cooling water, such as, but not limited to [0134] coolers comprised by the acid gas removal unit 11, such as [0135] a lean solvent cooler, comprised by acid gas removal unit 11, [0136] an acid gas removal unit intercooler, [0137] an acid gas removal unit condenser, [0138] an acid gas removal unit flash gas cooler and [0139] a flas gas compressor interstage cooler, [0140] a dehydration unit natural gas cooler, comprised by the dehydration unit 12, [0141] watercooled desuperheaters 1210 described above, [0142] coolers associated with the gas turbines (not shown) used to drive the first and second refrigerant compressor stages, such as [0143] gas turbine(s) intercooler(s), [0144] gas turbine air inlet coolers positioned in the air inlet of one or more gas turbines to cool the air being fed into the gas turbine to increase the efficiency of the gas turbine, [0145] condensate cooler and condensate stabilisation unit overhead compressor aftercoolers (not shown), [0146] various utility coolers.

[0147] It will be understood that according to a further embodiment, one or more of the above list of water cooled heat exchangers may be fed with chilled cooling water.

[0148] According to an embodiment, the gas turbine air inlet coolers are fed with chilled cooling water.

[0149] The system may comprise a controller C and a temperature measurement device T. The temperature measurement device T is arranted to obtaining an indication of the temperature of the stream of chilled cooling water 404, for instance by directly measuring the temperature of the stream of chilled cooling water 404.

[0150] The obtained indication of the temperature of the stream of chilled cooling water 404 is passed to the controller C, based on which the controller C controls the working duty of the chilling unit 411 to chill the first part of the stream of cooling water towards but not below a predetermined temperature. The controller C may control the chilling unit 411 to operate

[0151] at full capacity,

[0152] at a selected intermediate capacity, or

[0153] at zero capacity (i.e. to switch off).

[0154] It will be understood that one or more separation stages may be present as part of the first cooling stage 100 or in between the first and second cooling stage 100, 200, for instance a NGL extraction stage (not shown).

[0155] It will also be understood that the gas treatment stage 10 and the first and second cooling stages 100, 200 are depicted in a schematical manner and by means of example only.

[0156] Simulations

[0157] The embodiments described above with reference to FIGS. 1-4 were simulated in ProII.

[0158] In the simulation, an average feed temperature of the cooling water was set at 10 C and the chilled temperature was set at 4 C. The heat exchangers that received the second part of the cooling water thus received cooling water at a temperature of 10 C.

[0159] The simulations showed the following results: [0160] in the embodiment depicted in FIG. 1 approximately 13% of the cooling water was chilled resulting in a 0.6% increase of LNG production per degree C. of chilling. [0161] in the embodiment depicted in FIG. 2 approximately 22% of the cooling water was chilled resulting in a 0.7% per degree C. of chilling increase of LNG production. [0162] in the embodiment depicted in FIG. 3 approximately 76% of the cooling water was chilled resulting in a 0.87% per degree C. of chilling increase of LNG production. [0163] in the embodiment depicted in FIG. 4 approximately 84% of the cooling water was chilled resulting in a 0.97% per degree C. of chilling increase of LNG production.

[0164] For comparison, also a system was simulated in which all further water cooled heat exchangers that are present in the system were also supplied with chilled water, so effectively all cooling water being chilled, resulted in a 0.97% increase of LNG production.

[0165] The embodiments depicted in FIGS. 1 and 2 require a limited amount of chilling to reach a significant production gain, whereas the embodiments depicted in FIGS. 3 and 4 require a relatively large amount of chilling for an additional incremental production gain. It was therefore discovered that a focused selection of key process heat exchangers leads to an optimum production increase within the constraints of the LNG plant.

[0166] The person skilled in the art will understand that the present invention can be carried out in many various ways without departing from the scope of the appended claims.