INTEGRATED MULTI-FUNCTIONAL PIPELINE SYSTEM FOR DELIVERY OF CHILLED MIXTURES OF NATURAL GAS AND CHILLED MIXTURES OF NATURAL GAS AND NGLS
20230085320 · 2023-03-16
Inventors
Cpc classification
F25J2210/06
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25J1/0035
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F17D1/08
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25J1/0085
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25J1/0232
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25J1/0205
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25J1/0254
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25J1/0082
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25J2220/64
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25J1/0052
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25J1/0022
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F17D3/01
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25J1/0237
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F25J1/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F17D1/08
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F17D3/01
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
Herein pipeline pressure, temperature and NGL constituents are manipulated for the transportation and optional storage in a pipeline system of natural gas mixtures or rich mixtures for delivery of chilled Products for downstream applications. Pressure reduction from a last compression section delivers internally chilled Products for reduced capital and operating costs. A high lift compressor station before the pipeline terminus provides pressure differential for Joule-Thompson chilling of the pipeline contents. The chilling step can be retrofitted to existing pipeline systems, and the chilling steep can include a turbo expander or the like for recovery of pipeline pressure energy for power generation. For like throughout, with this higher pressure operation, the effects of enhanced NGL content results in a reduction in diameter of the pipeline by at least one standard size. Substantial overall reduction in energy consumption and associated CO2 emissions is thereby achieved through integrated pipeline/processing applications.
Claims
1.-16. (canceled)
17. A method for producing chilled standard specification and rich gas specification natural gas mixtures comprising the steps of: (a) compressing a natural gas mixture received from a natural gas pipeline to a pressure range of between 2500 psig and 4500 psig to produce a compressed gas mixture; (b) storing a volume of the compressed gas mixture in a supercritical state at a pre expansion pressure range of between 2500 psig and 4500 psig; and (c) expanding the compressed gas mixture using an expansion chilling device in the form of a J-T valve or a turbo expander, to achieve self chilling through the Joule-Thomson effect and to produce a chilled gas mixture; wherein the chilled gas mixture has a temperature of between minus 20° F. and minus 100° F.; and wherein the chilled gas mixture has a pressure of between 1200 psig and 800 psig without liquid fallout.
18. The method of claim 17 wherein the natural gas mixture received from the natural gas pipeline has a pressure of over 2250 psig.
19. The method of claim 17 wherein the pre-expansion pressure range is between 2500 psig and 3250 psig.
20. The method of claim 17 further comprising, before step (a), the step of transmitting the natural gas mixture along the natural gas pipeline with recompression beginning at 1300 psig or greater to a pressure of up to about 2500 psig.
21. The method of claim 17 wherein the chilled gas mixture has a temperature of between minus 60° F. and minus 100° F.
22. The method of claim 17 wherein the turbo expander is coupled for energy recovery through an output shaft to a mechanical device.
23. The method of claim 17 wherein the turbo expander is coupled for energy recovery through an output shaft to an electrical generation device.
24. The method of claim 17 wherein the turbo expander is coupled for energy recovery through an output shaft used directly for upstream or downstream compression.
25. The method of claim 17 wherein the natural gas mixture from the pipeline comprises the following constituents: from 40% to 98% by mol volume of methane; from trace to 35% by mol volume of ethane; from trace to 22% by mol volume of propane; from trace to 9% by mol volume of butane; residual amounts of total N2 not exceeding 2% by mol volume; C5+ hydrocarbons not exceeding 0.25 of mol volume; the total volume of these constituents being 100%; and wherein the natural gas mixture does not exhibit a liquid fraction during any step of the method.
26. The method of claim 17 wherein the natural gas mixture from the pipeline comprises the following constituents: from 55% to 94% by mol volume of methane; from 6 to 25% by mol volume of ethane; from trace to 22% by mol volume of propane; from trace to 8.5% by mol volume of butane; residual amounts of N2 not exceeding 2% by mol volume; C5+ hydrocarbons not exceeding 0.25% of mol volume; the total volume of these constituents being 100%; and wherein the natural gas mixture does not exhibit a liquid fraction during any step of the method.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0055] In the following description, reference is made to the accompanying drawings:
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DETAILED DESCRIPTION OF THE EMBODIMENTS
[0077] Having reference to
[0078] In
[0079] In
[0080] In
[0081] The pipeline transmission staging section 102 comprises one or more pipelines 112 for moving natural gas mixture, and one or more compressors 114 for recompression of the natural gas mixture at each section to a higher pressure. Thus, the pipeline staging section 102 transmits natural gas mixture within desired pressure and temperature ranges.
[0082] In embodiments, the natural gas mixture is a Standard Gas mixture Rich Gas mixture, formulated by additive or subtractive processing, and comprising: from 40% to 98% by molar volume (mol volume) of methane, from trace to 35% by mol volume of ethane, from trace to 22% by mol volume of propane, from trace to 9% by mol volume of butane, and trace elements of C5+(i.e., C5, C6, . . . ) hydrocarbons not exceeding 0.25% by mol volume; and the total of (a) to (e) being 100%, and such mixture being completely gaseous or dense phase (supercritical) with no liquid phase at the temperature and pressure of operation.
[0083] The pipeline extends from the source to the destination, through a series of recompression cycles. One or more, or all of recompressions raise the Rich Gas to a maximum operating pressure (MOP), having a Rich Gas mixture adjusted to avoid liquid fallout. The re-compression pressure is raised of over about 2250 psig and in further embodiments between MOP of about 2250 to about 2850 psig. As energy and pressure is lost over the 100 or more kilometer transmission between compressor stations, recompression can occur at about 1500 psig or at recompression thresholds of between about 1500 to about 1900 psig to attain the described hydraulic and compressive power benefits from optimum compressibility Z values. Further, as the volumetric efficiency of the Rich Gas mixture is improved, one can reduce in pipe diameters by at least one standard size over those for prior lower pressure designs for reduced capital cost whilst moving the same mass of Rich Gas.
[0084] In this embodiment, and in greater detail, the pipeline staging section 102 operates with a maximum operating pressure (MOP) of 2500 psig and recompression at 1300 psig, utilizing a range of low compressibility factors Z range, Point A to Point B to Point C of
[0085] Transmission pipeline compressors are shown as “C” types. In the final Storage/Delivery pipe section 104 the pressure is lifted through stepped compressors “Cx” from 1300 psig to 3000 psig storage to provide the head for de-compression (D-E). This drop in pressure at the exit of the storage section reduces the storage temperature via Joule-Thompson effect on the flowing products to −45 F as shown here. Depending on the gas mixtures and pressure drop, much lower temperatures in accordance with downstream Application can be provided.
[0086] The above described arrangement of transportation management and the use of above described rich gas mixture provide a synergy in pipeline operations resulting in an option to use smaller pipe diameters for same transmission capability and while reducing compressive power needed for Rich Gas pipelines.
[0087] Further, the final pressure and temperature conditioning of the natural gas, departing the Turbo Expander into pipeline section 106 at the destination, results in large savings in both capital and operational costs to produce the delivered product in a form that eliminates the need for the first stage chilling of the certain downstream applications. Overall, the capital costs of such pipeline systems are reduced over conventional natural gas transportation systems.
[0088] The higher transmission efficiency and thus the lower cost of the pipeline system disclosed herein is obtained by transmitting natural gas mixtures, such as the rich gas mixture disclosed herein, at desired pressure and temperature ranges to achieve a lower compressibility factor (Z) substantially throughout during transmission.
[0089] With reference to
[0090] With reference to
[0091] Both the pipeline hydraulics and net storage densities are improved by incorporating a lower Z value in the system design by virtue of the NGL constituents in the gas mixture. The process disclosed herein takes advantage of the accumulated effects of stored density and pipeline hydraulics to elevate the transmission economics to another level. A typical MOP of a pipeline carrying Standard Transmission specification gas mixture at about 1450 psig at 75° F. (see point S of
[0092] Whereas prior teaching advocated running Rich Gas mixture pipelines between 2100 psia and 1300 psia (left of Point B to Point C of
[0093] Now a pipeline carrying above described rich gas mixture can run between 2500 psia, Point A, through the prior known low Z value at 2100 psia at Point B, and even lower down to a pressure of about 1300 psia to 1500 psia in the region of Point C before recompression.
[0094] The recompression point depends on station spacing and pipe diameter relative to pipeline flow rate. This wider recompression pressure cycle, or wider operating pressure range, also permits longer distances between compressor stations for reduced capital expenditure.
[0095] Optimally designed, the operation of the rich gas pipeline at the new higher MOP towards Point A can result in a 12% increase in flow for less power per unit of gas over the performance of the earlier designs with a MOP at Point B.
[0096] In an embodiment, by recompressing at about 1300 to about 1450 psia, at about Point C, Applicant found new operating efficiencies that outweigh the required increase in pipe wall thickness demanded by the higher MOP. Compared to conventional pipeline systems, the average Z value drops from 0.705 to 0.682, and the compressor station spacing increases by 15%, easily removing one complete compressor station from the infrastructure of a typical 1000 mile long-distance pipeline. For example, conventional spacing of one station per 100 miles might be increased to one station per 120 miles, further reducing capital cost and complexity.
Storage for Compressor Outage Situations:
[0097] Referring to
[0098] With reference to
[0099] The phase remains gaseous without liquid fall out throughout the transmission of the Product to Downstream Applications.
[0100] Point 176 marks the Maximum Operating Pressure (MOP) to which the gas is compressed in a mainline segment to 2500 psig. The pressure and temperature drop as the Product flows along the segment to the point of Re-Compression at point 174, 1750 psig. For normal flow from segment to segment, the gas would be compressed back to MOP level at 2500 psig and the cycle begin again.
[0101] However, for illustration the compression here is taken from point 174 to point 178 at 3250 psig, representing the containment condition in a high pressure storage stage of the pipeline where the mixture can be held under conditions of high density. The storage volume for the product would be dependent on the project-specific pipe volume made available here. From point 178 to point 180 the Product is seen to drop rapidly in pressure towards 1200 psig. This flow takes place in a J-T device such as a turbo expander, and temperature is noted to chill, in one embodiment, from 90 F to 1° F. as a result of the Joule-Thompson effect on the flowing medium, which is now available for delivery. These delivery conditions avail themselves for a selection of downstream applications. Far lower temperatures can be experienced for specific process needs by adjustment of inlet pressure and outlet pressure across the J-T device.
Storage for Delivery Demand:
[0102] The accumulator or storage staging section 104, usually located at the destination, comprises one or more storage pipes 122, and a Joule-Thomson (J-T) expander 132 (described later) for transmitting rich gas from the storage pipes to the trans-shipment staging section 106. A high, and last stage, pressure booster compressor station 116 can be located between staging sections 102 and 104 and has a high head capability to lift the pressure up from above described, normal operating pressures to a desired elevated storage pressure in the storage pipes 122.
[0103] In some embodiments each of the storage pipes 122 is a pipe having a longer section length and a larger diameter (“A” to “B” of
[0104] In one embodiment, the Rich Gas mixture disclosed herein may be contained in the storage pipes 122 at pressures between about 3250 psig and about 3500 psig, depending on liquid fallout limits of the particular gas mixture, and preferably at ambient/ground temperatures. About 110° F. has been noted in modeling summer operations where limitations of air cooling and residence times in the pipeline have not proved to be prohibitive to in-pipe storage. In temperate zone winter conditions about 75° F. or lower is the norm for flow emerging from storage. This lower temperature is the basis for J-T chilling summarized for Standard Specification and Rich Gas mixes in
[0105] An optional temperature trimming system is incorporated within or downstream of the storage compressors to condition the gas flow to optimal temperature or density conditions for process applications downstream of the invention. Where the pipeline is specifically designed to handle expansion, stress and material behavior, an operating condition, upper temperature limit of 150° F. is specified to maintain flow in gaseous state when the pipeline is installed in cold environments having high heat losses along the sectional length(s).
Storage where Other Facilities are Unavailable:
[0106] Such an accumulator storage system takes advantage of the available conventional pipeline installation equipment, techniques and inspection and quality control aspects implemented for the pipelines 112 in the pipeline staging section 102. For example, three (3) parallel 36″ pipes can be used as the storage pipes 122 between the last compressor station 116 and the trans-shipment staging section 106. As a result, excessive costs or lack of onsite storage or caverns are no longer prohibitive at the destination or shipping point of the system 100. Thus, the storage staging section 104 ahead of the shipping point can now incorporate a large volume by means of pipes 122. Alternatively, the pipes 112 may be a mix of pipes of different lengths and/or diameters for holding this strategically determined volume.
[0107] The increased diameter(s)/cross-section(s) or combined diameter(s)/cross-section(s) of the storage pipes 122 in the storage staging section 104 further reduce the hydraulic pressure loss that may be experienced by the conventional pipeline system during normal operating conditions.
Storage Energy Chilling and Transposition:
[0108] As shown in
[0109] The J-T expander 132 reduces adiabatically the pressure of the natural gas mixture, or in one embodiment the rich gas mixture, from the high storage pressure (about 3250 to 3500 psig) to approximately 1300 psig. Such a pressure drop at the J-T expander 132 results in J-T cooling to the natural gas mixture passing therethrough for trans-shipment at optimal conditions illustrated in
[0110] Using the energy in the high pressure accumulated Rich Gas mixture, the J-T expander acts as an internal chiller that, dependent on the destination demands, may be all the chilling that is required. The J-T expander 132 may be any gas expander and ancillary equipment suitable for reducing the pressure of the natural gas mixture and for chilling the natural gas mixture using the Joule-Thomson effect (i.e., internal, or self-chilling). For example, in one embodiment, the J-T expander 132 is a pressure reduction valve; in another embodiment and more efficiently, the J-T expander 132 is an energy recovering turbo expander. As is known in the art, the Joule-Thomson effect refers to the phenomenon that, with no heat exchange with the environment, the temperature of a gas changes when it is forced through a flow restrictor.
[0111] In one embodiment, the J-T expander 132 uses the J-T effect to chill the natural gas mixture to a low temperature suitable for trans-shipment without liquid fallout, e.g., in some embodiments to between about −20° F. and about −30° F. for Rich Gas Mixtures, or in other embodiments to between about −10° F. and about −80° F. for Standard Specification Gas. Whereas carbon steels are generally limited in service to −55° F., utilizing these lower temperatures is dependent upon the materials of construction with lower limits such as nickel steels, aluminum and stainless steel.
[0112] With reference to
Energy Recovery as Electrical Generation:
[0113] In another embodiment where a turbo-expander is used for polytropic expansion, lower temperatures are achievable along with energy conservation by recovering energy through generation of electricity or mechanical power from its output shaft.
[0114] Recovered power from the turbo expander and chilled fluid emerging from the pipeline system present a more efficient means of providing external and downstream energy needs. The generated power can also exported off site.
[0115] Chilling to downstream processing production is provided more efficiently from pipeline compression. Given the additional External Chilling requirements for compression, heat transfer, fouling interface, and re-condensing the internal chilling availability from this invention will eliminate over half the expected energy load. In an embodiment, over a range of temperatures between 110 F and −40 F, internal chilling exhibits a nominal overall efficiency of general order of 28% compared to external chilling showing a general order of 12% overall efficiency.
Downstream Options:
[0116] Alternative pre-chilled feed stock can be provided from header 134 shown in
[0117] While located adjacent a terminus in one embodiment for J-T cooling, as shown in
[0118] In an alternative embodiment the storage pipes 122 can operate at a high pressure up to 4500 psig for increasing process storage density. At such high pressures the J-T effect on the contained Products is minimal, an external trimming cooler system is coupled to the J-T expander to reduce the discharged natural gas mixture to optimal temperature for colder temperature downstream applications.
[0119] In alternative embodiments, traditional Standard Transmission specification gas mixture may be transmitted in the disclosed high-pressure pipeline system 100. For example, in one embodiment, Standard Transmission specification gases may be transmitted in the high-pressure pipelines 112 operating between an MOP of about 2750 psig and recompression at 1650 psig or 1700 psig for transmitting the Standard Transmission specification gases at a low Z factor for improved gas transmission efficiency.
[0120] In an alternative embodiment, an external trimming cooler system can also be coupled to the J-T expander 132 to reduce the discharged natural gas mixture to optimal temperature or density conditions for alternate specified downstream applications.
Influence of Gas Constituents Carried by Pipeline:
[0121] Given the multiplicity of combinations of affective NGL constituent combinations possible in Rich Gas mixtures it is convenient to illustrate the benefits and limitations of mixtures against Standard Transmission specification gas mixtures, modeled as straight methane (C1), and the Rich Gas modeled as 2-part mixtures of methane and each of one of the three common and principal NGL constituents of ethane (C2), propane (C3), and butane (C4) and modelling Standard Transmission specification gas as simple methane.
[0122] In the following, the benefits of the disclosed two-component Rich Gas mixtures are described with reference to
[0123] In the graphs of
[0124] In the
[0125] At a pressure of 1200 psig at temperatures of −40° F. and −30° F. the v/v ratio of the two mixtures show useful increases of the order of 35% for the Rich Gas over the Standard Transmission specification mixture.
[0126] There is a clear distinction between the two gas types in the comparative mass ratio plots. The useful value of 247 VN for the net volumetric ratio of Rich Gas at 1200 psig and −20° F. yields a lb/lb gas to containment material mass ratio of 0.40 exceeding the 0.22 number for CNG (from Standard Transmission specification gas mixture) under the same conditions. The mass ratio of the containment system for methane constituent in the Rich Gas is virtually doubled here over that for CNG when stored in this manner for onward transportation/storage in containment vessels, resulting in significant capital cost savings.
[0127]
[0128] For propane rich constituents the best compressive performances for storage of the gaseous Rich Gas mixture measured against the Standard Transmission specification mixture appear in the 900 to 1400 psig range of pressures at temperatures in the −30° F. to −20° F. window suited to steel containment.
[0129] At a pressure of 1200 psig at temperatures of −30° F. and −20° F. the v/v ratio of the optimal mixtures show useful increases of the order of 69 to 60% for the Rich Gas. At colder temperatures, and higher pressures it is evident that instabilities of liquid formation and fallout is to be avoided for richer mixtures.
[0130] There is a clear distinction between the two gas types in the comparative mass ratio plots. The useful value of 250 for the volumetric ratio of Rich Gas at 1200 psig and −20° F. yields a lb/lb gas to containment material mass ratio of 0.38 exceeding the 0.22 number for CNG under the same conditions. The mass ratio of the required containment system is reduced to 2/3 here when Rich Gas is stored for transportation. Conversely similar containment performance of Standard Transmission specification mixture would call for that product to be stored at 1400 to 1800 psig at a temperature of −40° F. with a corresponding increase in wall thickness of the steel
[0131]
[0132] Best compressive performances for storage of the gaseous Rich Gas mixture measured against the Standard Transmission specification mixture appear in the 900 to 1200 psig range of pressures at temperatures in the −30° F. to −20° F. window suited to steel containment.
[0133] At a pressure of 1200 psig at temperatures of −30° F. and −20° F. the v/v ratio of the two mixtures show useful increases of the order of to 45% for the Rich Gas over Standard Transmission specification mixture. At colder temperatures, and higher pressures it is evident that instabilities of liquid formation and fallout is to be avoided for richer mixtures.
[0134] There is a clear distinction between the two gas types in the comparative mass ratio plots. The useful value of 229 for the volumetric ratio of Rich Gas at 1200 psig and −20° F. yields a lb/lb gas to containment material mass ratio of 0.37 exceeding the 0.22 number for CNG under the same conditions. The mass ratio of the containment system is less than 2/3 here when Rich Gas is stored for transportation. Conversely similar containment performance of Standard Transmission specification mixture would call for that product to be stored at 1400 to 1800 psig at a temperature of −40° F.
[0135] With reference to the graphs of
[0136] Performance for storage of the gaseous Rich Gas mixture (for the NGL constituent represented by ethane (C2), measured against the Standard Transmission specification mixture, appears in the 1100 to 1400 psig range of pressures at temperatures in the −30° F. to −20° F. window, balancing increased compressed volume ratio against mass ratio.
[0137] At a pressure of 1200 psig at temperatures of −40° F. and −30° F. the v/v ratio of the two mixtures show useful increases of the order of 35% for the Rich Gas over the Standard Transmission specification mixture.
[0138] There is a clear distinction between the two gas types in the comparative mass ratio plots. The useful value of 247 VN for the net volumetric ratio of Rich Gas at 1200 psig and −20° F. yields a lb/lb gas to containment material mass ratio of 0.40 exceeding the 0.22 number for CNG (from Standard Transmission specification gas mixture) under the same conditions. The mass ratio of the containment system for methane constituent in the Rich Gas is virtually doubled here over that for CNG when stored in this manner for onward transportation/storage in containment vessels, resulting in significant capital cost savings.
[0139]
[0140]
[0141]
[0142] In
[0143] Best compressive performances for storage of the gaseous Rich Gas mixture measured against the Standard Transmission specification mixture appear in the 900 to 1400 psig range of pressures at temperatures in the −30° F. to −20° F. window suited to steel containment.
[0144] At a pressure of 1200 psig at temperatures of −30° F. and −20° F. the v/v ratio of the optimal mixtures show useful increases of the order of 69 to 60% for the Rich Gas. At colder temperatures, and higher pressures it is evident that instabilities of liquid formation and fallout is to be avoided for richer mixtures.
[0145] There is a clear distinction between the two gas types in the comparative mass ratio plots. The useful value of 250 for the volumetric ratio of Rich Gas at 1200 psig and −20° F. yields a lb/lb gas to containment material mass ratio of 0.38 exceeding the 0.22 number for CNG under the same conditions. The mass ratio of the required containment system is reduced to 2/3 here when Rich Gas is stored for transportation. Conversely similar containment performance of Standard Transmission specification mixture would call for that product to be stored at 1400 to 1800 psig at a temperature of −40° F. with a corresponding increase in wall thickness of the steel
[0146]
[0147]
[0148] In
[0149] Best compressive performances for storage of the gaseous Rich Gas mixture measured against the Standard Transmission specification mixture appear in the 900 to 1200 psig range of pressures at temperatures in the −30° F. to −20° F. window suited to steel containment.
[0150] At a pressure of 1200 psig at temperatures of −30° F. and −20° F. the v/v ratio of the two mixtures show useful increases of the order of to 45% for the Rich Gas over Standard Transmission specification mixture. At colder temperatures, and higher pressures it is evident that instabilities of liquid formation and fallout is to be avoided for richer mixtures.
[0151] There is a clear distinction between the two gas types in the comparative mass ratio plots. The useful value of 229 for the volumetric ratio of Rich Gas at 1200 psig and −20° F. yields a lb/lb gas to containment material mass ratio of 0.37 exceeding the 0.22 number for CNG under the same conditions. The mass ratio of the containment system is less than 2/3 here when Rich Gas is stored for transportation. Conversely similar containment performance of Standard Transmission specification mixture would call for that product to be stored at 1400 to 1800 psig at a temperature of −40° F.
[0152]
[0153]
[0154] Based on an upper limit of inlet flow of one billion ft3/day, and operating at an MOP of 1440 psig, for 1000 miles of transmission, the conventional pipeline system requires a mass of steel of about 463,913 US tons, and the Rich Gas high pressure pipeline of smaller diameter, system 200, requires a mass of steel of about 499,799 US tons. Although the design of the Rich Gas system 200 requires fractionally more mass of steel, it achieves higher daily heat value delivery per US ton steel (2.411 million BTU/US Ton Steel vs. 2.217 million BTU/US Ton Steel). The smaller diameter of system 200 is not restricted to the comparative inlet flow rate of 1.0 billion ft3/day used here for comparative purposes and can achieve a still higher daily heat value delivery per US ton steel. In system 201, which is essentially system 200 subjected to a higher flow rate and velocity restrictions, the delivered heat value ratio is seen to increase by the order of +30%, depending a higher flow rate and velocity limitations). See system 201.
[0155] Further,
[0156]
[0157]
[0158] The gas stream leaves the pipeline/storage system via the turbo expander 132 that both chills the gas as its pressure drops and generates shaft power that can be converted into electricity W. The flowrate is monitored at a custody transfer point C. An opportunity exists here downstream of custody transfer to ship an optional side-stream C-R-G of compressed Chilled Rich Gas to an export point ahead of LNG processing. An opportunity here also exists for an auxiliary process chilling flow C-V of product to be withdrawn.
[0159] The main pipeline delivery flow destined for the LNG plant passes into the first stage chiller LNG1 at point D where all or most of the chilling normally supplied by a propane refrigeration plant is replaced by the pipeline outflow. This unit chills the LNG plant feedstock passing through the heat exchanger from point H to point K.
[0160] From Point E the flow goes to Point F where it enters a separation tower SP1 where NGL liquids are extracted (departing the tower at Point J) leaving behind a lean gas stream of mostly methane and some ethane that forms the basis of the LNG feedstock. This product flows from point G to the inlet of the first stage chiller LNG 1 at point H. It will generally not require any intermediate processing with correct operation of the separation tower SP1 that is ideally specified as an absorbent process.
[0161] From chiller LNG1 the LNG feedstock enters a second stage chilling process LNG 2 at Point L. This chiller uses a refrigerant such as ethylene outside of the temperature range and scope of this invention onroute to the LNG production of the plant.
[0162] The separation unit SP1 has a loop for regeneration of adsorbent fluid through a process skid RG1. The previously mentioned chilled side-stream of pipeline outflow of cold rich gas CV is used in the chiller section of this skid. The chilling stream enters the RG1 unit at W, leaving at X to rejoin intercept at point V and reunite with the mainstream flow EF emerging from the Chiller LNG 1.
[0163] This disclosure discusses a method of accelerating the onset of, and access to, lower compressibility (Z) factors in natural gas pipelines covering embodiments of broader pressure, temperature, and constituents within Rich Gas mixtures yielding a new array of transportation benefits. A wider band of low flow resistance in pipelines over that in the prior art which restricted by lower maximum operating pressures. Storage density is improved. The properties of the Rich Gas mixtures and higher operating/storage pressures involved are such that internal chilling within the transported medium can then take place through the Joule-Thompson effect and making a chilled, lower pressure delivery of product direct from the pipeline.
[0164] The subsequent delivery of a chilled product using recovered pipeline energy can replace a substantial amount of chilling otherwise externally created for many downstream applications.
[0165] The ability to take advantage of high levels of NGLs within the new gas mixtures and their behavior within the broader pipeline pressure differentials (sitting within 3500 psig and 900 psig) for this invention enables the Joule-Thompson effect of “internal” chilling to occur within the product transported by the pipeline. This chilling matches or exceeds that of external chilling via heat exchangers commonly found in the downstream gas processing industry to be working below 800 psig and 1300 psig plant design thresholds. These industrial refrigerants here are frequently non-hydrocarbon in nature and increasingly being withdrawn from the market in the interests of their more severe environmental impact.
[0166] Having a pre-chilled product delivered by the pipeline will alleviate this demand on the industry, and when provided via turbo expander recover pipeline energy often lost in the custody transfer between segregated pipeline and process disciplines.
[0167] Design developments incorporated herein permit simplified operations within a broader pressure range of low compressibility factor (Z) operation to take place. Pre-conditioning processing in the field is simplified, mainline compressor stations can incorporate single units. Operating pressures now broaden between 2500 psig through the best efficiency point around 2100 psig to the recompression point about 1300 psig or about 1450 psig, depending on gas mixture.
[0168] On a project specific basis there is nothing to preclude design and construction of all sections of the pipeline to a high MOP of 3500 psig encompassing hydraulic, storage and chilling benefits claimed by this invention throughout its length.
[0169] Reduced capital expenditure, compression infrastructure and operating costs emerge from this less energy and emissions intensive Rich Gas transmission, chilling and containment system. The need and environmental impact of multiple pipelines, rail and trucking movements for gas and NGL transport is eliminated or takes place through seamless integration of new process plant and retrofitting of existing infrastructure to meet future demands on the industry.
[0170] As a result and enabled herein, embodiments include a method of bringing about the chilling of Natural Gas and Natural Gas/NGL mixtures delivered from a pipeline system such that the resulting mixture also exhibits internal chilling behavior during its transport, storage, and withdrawal from the system that is associated with behavior properties of the constituents of the conveyed product. Such mixtures can be formulated by additive or subtractive processing of the natural gas and NGL constituents. Operational conditions where these effects occur can be between 3500 psig and 500 psig and 120 F and −120 F. The low temperature range being reserved for the lightest mixtures not exhibiting liquid fall out.
[0171] The method replaces or reduces the need for externally provided chilling traditionally applied in downstream processing of the delivered products. Notwithstanding the types of process here include but are not limited to pre chilling for LNG production, chilling for separation and fractionation, and chilling for enhanced storage of CNG.
[0172] In another aspect, a method of high pressure pipeline transmission and systems of storage for Natural Gas mixtures and Natural Gas/NGL enhanced mixtures is provided, the mixtures formulated with the objective of lowering compressibility (Z) factors under Maximum Operating conditions (MOP) between above about 2150 psig and up to about 4500 psig. Such mixtures can be formulated by additive or subtractive processing of the natural gas and NGL constituents.
[0173] In an example of the range of effective gas mixtures applicable comprise: from 40% to 98% by mol volume of methane, from trace to 35% by mol volume of ethane; from trace to 22% by mol volume of propane; from trace to 9% by mol volume of butane; residual amounts of N2 not exceeding 2% by mol volume; trace elements of C5+ (ie C5, C6 . . . ) hydrocarbons not exceeding 0.25% of mol volume; and the total being 100%, wherein the operating conditions of the mixture is completely gaseous or in the supercritical-dense phases with no liquid phase.
[0174] Notwithstanding, the mol % of any of the Light Hydrocarbons (ethane, propane, butane) given here can also lie within the 0 to specified minimum % mol range as shown, where the stand alone % mol of remaining Light Hydrocarbons is sufficient to bring about the reduction in Z factor value and dense phase flow/storage behavior and/or chilling effects.
[0175] Such stand alone values are 6% for ethane, 1.5% for propane and 0.5% for butanes for Rich Gas mixtures: and 2% for ethane, 1% for propane and 0.25% for butanes in the 2500 psig or higher pressure Standard Transmission specification mixtures.
[0176] Turning to the storage aspect, a high pressure staged section of the pipeline, that is project specific in volume by virtue of length and cross sectional area, can be used for high pressure storage, product flow and de-pressuring of the pipeline contents, which operates within the limits of 3500 psig and 800 psig according to end use for the delivered product. Such as system can also be operated within the limits of 4500 psig and 800 psig according to end use for the delivered product.
[0177] Regarding the internal chilled through Joule Thompson effect, a pressure and temperature reducing device such as a J-T valve or Turbo Expander is located at the exit points of the pipe sections that will bring about the refrigeration effect within the transmitted gas mixture subjected to the pressure drop. Preferably a turbo expander system is employed that permits shaft or electrical recovery of pipeline energy from the high pressure storage. Despite the chilled effects achieved using embodiments described herein, and where internal chilling is insufficient, an optional temperature trimming system incorporated within or downstream of the storage compressors to condition the gas flow to optimal temperature or density conditions for process applications downstream of the invention.
[0178] In embodiments where the pipeline is specifically designed to handle expansion, stress and material behavior, an upper temperature limit of 150 F is claimed for operating conditions to maintain flow in gaseous state when the pipeline is installed in cold environments with high heat losses along the sectional length(s).
[0179] A pipeline can be configured to carry lean North American Spec Gas or NGL Rich Gas, that is project specific in volume, by virtue of its entire length and cross sectional area and pipe layout, used for product flow, high pressure storage, and de-pressuring the contents, which operates within the limits of 4500 psig and 350 psig according to end use for a chilled delivered product.