Methods and devices for drying hydrocarbon containing gas
09689608 ยท 2017-06-27
Assignee
Inventors
Cpc classification
F25J3/061
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25J3/0645
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25J2240/90
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25J2230/20
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25J3/0635
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25B9/04
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25J3/064
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F25J3/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
C10L3/10
CHEMISTRY; METALLURGY
F25J3/06
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
Processes and devices for recovering natural gas liquid from a hydrocarbon containing gas are provided by introduction of compressed air to a vortex tube. The vortex tube generates a cold air stream that is introduced into a heat exchanger. A hydrocarbon containing gas of higher temperature than the cold air stream is introduced into the heat exchanger, so that the cold air stream in the heat exchanger cools the hydrocarbon containing gas to condense natural gas vapors in the hydrocarbon containing gas to liquid hydrocarbons. In this manner, liquid hydrocarbons and dry hydrocarbon containing gas are obtained.
Claims
1. A process for recovering natural gas liquid from a hydrocarbon containing gas, said method comprising the steps of: mechanically coupling a boundary layer disk turbine (BLDT) to a compressor pump; directing a flow of pressurized fluid of the BLDT to mechanically power the compressor pump; compressing air with the mechanically powered compressor pump; thereby generating compressed air without an external energy source; introducing said compressed air to a vortex tube; separating the introduced compressed air in the vortex tube into a hot air stream and a cold air stream; introducing the cold air stream into a heat exchanger; introducing the hydrocarbon containing gas into the heat exchanger, wherein the cold air stream in the heat exchanger cools the hydrocarbon containing gas thereby condensing natural gas vapors in the hydrocarbon containing gas to liquid hydrocarbons; collecting the liquid hydrocarbons from the heat exchanger; and collecting a dry hydrocarbon containing gas from the heat exchanger; thereby recovering natural gas liquid from the hydrocarbon containing gas without an external energy source.
2. The process of claim 1, wherein the introduced compressed air has a pressure selected from a range that is greater than or equal to 80 psi and less than or equal to 120 psi.
3. The process of claim 1, wherein the introduced compressed air has a temperature selected from a range that is greater than or equal to 50 F. and less than or equal to 90 F.
4. The process of claim 1, wherein the introduced compressed air has a temperature that is within 10 F. of surrounding ambient air temperature.
5. The process of claim 1, wherein the cold air stream from the vortex tube has a temperature selected from a range that is greater than or equal to 20 F. and less than or equal to 20 F.
6. The process of claim 1, wherein the cold air stream has an exit temperature from the vortex tube that is at least 30 F. to 100 F. less than an introduction temperature of the introduced compressed air.
7. The process of claim 1, wherein the cold air stream has a user-selected flow rate.
8. The process of claim 1, wherein the compressed air is stored in a storage tank.
9. The process of claim 1, wherein the pressurized drive fluid is a vapor gas from a hydrocarbon containing liquid.
10. The process of claim 1, further comprising the step of providing on-demand control of a pneumatic device within the process.
11. The process of claim 1, wherein the hydrocarbon containing gas introduced to the heat exchanger is from a separation tank or a production field and comprises condensable hydrocarbons of C2 or greater.
12. The process of claim 11, wherein the mole percentage of the condensable hydrocarbons is 20% or greater.
13. The process of claim 1, wherein the collected dry hydrocarbon gas comprises methane hydrocarbons in an amount that is greater than or equal to 95 mol %.
14. The process of claim 1, wherein the collected dry hydrocarbon gas is provided to a sales line or combusted.
15. The process of claim 1, wherein the collected NGL comprises one or more of: ethane, butane or propane.
16. The process of claim 1, wherein the collected NGL is stored in a containment vessel or introduced to a sales pipeline.
17. An apparatus for recovering natural gas liquids from a hydrocarbon-containing gas, the apparatus comprising: a heat exchanger comprising: a first inlet for receiving a hydrocarbon stream comprising wet natural gas, a first outlet for releasing a cooled hydrocarbon stream that is dry natural gas from the hydrocarbon stream, a second inlet for receiving a cold air stream; a second outlet for releasing a heated air stream, wherein the cold air stream and the hydrocarbon stream comprising wet natural gas are in thermal contact, and the cold air stream cools the hydrocarbon stream to provide the dry natural gas and the heated air stream; and a third outlet for releasing a condensed natural gas liquid (NGL) from the cooled hydrocarbon stream; a vortex tube for separating compressed air into the cold air stream at a first end and a hot air stream at a second end; a cold air stream conduit that fluidly connects the vortex tube first end to the heat exchanger second inlet for introducing the cold air stream to the heat exchanger; and a NGL collection vessel connected to the heat exchanger third outlet for collecting a condensed NGL from the cooled hydrocarbon stream; a self-powered compressor that provides compressed air to the vortex tube, said self-powered compressor comprising: a boundary layer disc turbine (BLDT); a source of pressurized drive fluid; a pressurized drive fluid conduit that fluidically connects the BLDT and the source of pressurized drive fluid; a compressor pump mechanically connected to the BLDT; an air source fluidically connected to the compressor pump; wherein flow of pressurized drive fluid under a pressure differential mechanically powers the compressor pump to compress air to a desired pressure for introduction to the vortex tube.
18. The apparatus of claim 17, further comprising a compressed air storage tank fluidically connected to the compressor pump for storing compressed air.
Description
DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION OF THE INVENTION
(7) The invention may be further understood by the following non-limiting examples. All references cited herein are hereby incorporated by reference to the extent not inconsistent with the disclosure herewith. Although the description herein contains many specificities, these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the presently preferred embodiments of the invention. For example, thus the scope of the invention should be determined by the appended claims and their equivalents, rather than by the examples given.
(8) Hydrocarbon containing gas is used broadly to refer to a gas that contains hydrocarbon materials, such as natural gas from a gas field production or gas from a separator tank. Accordingly, the hydrocarbon containing gas can be a mixture of hydrocarbon gases, including methane and higher-chain carbons such as ethane, propane, butane, etc. Wet hydrocarbon containing gas refers to gas containing condensable vapors, such as C.sub.2+. In the processes provided herein, such condensable vapors are at least partially condensed from the hydrocarbon containing gas by an exchange of heat with a cold air stream so as to condense higher-chain hydrocarbons, thereby increasing the relative amount of methane in the hydrocarbon containing gas (referred herein as dry hydrocarbon containing gas). In an aspect, dry refers to at least 95% or greater (by mol %) gas composition is methane. In an aspect, dry refers to a composition that is between 95% and 99%, 97% to 99%, or about 98% to 99% methane (by mol %).
(9) Natural gas liquid or NGL refers to heavier hydrocarbons that have been condensed from wet hydrocarbon containing gas, such as C.sub.2+ (e.g., ethane, propane, butane, and higher). The NGL may be a mixture of hydrocarbons or, as desired, individually separated. The NGL collected herein may be stored, provided to a liquid gathering line, or further cooled to generate liquefied natural gas for easier storage or transport.
(10) Compressed air refers to air that is at a pressure higher than atmosphere. The compressed air may be directly from a compressor that compresses air to a desired pressure. Alternatively, the compressed air may come from a source of compressed air, such as air stored in a storage tank or vessel and provided on demand.
(11) Vortex tube refers to a mechanical device that separates a compressed gas, in this example compressed air, into hot and cold streams. Such vortex tubes are also known in the art as Ranque-Hilsch vortex tubes. Vortex tubes are known in the art, including as described U.S. Pat. Nos. 6,932,858, 5,483,801, 3,208,229, 3,173,273, and 3,775,998 which are specifically incorporated by reference herein for vortex tubes and related components for controlling and processing fluids. Depending on the application of interest and associated operating conditions, a wide range of vortex tubes may be employed herein, so long as the vortex tube provides the desired cooling and flow rates as required by the input wet hydrocarbon containing gas.
(12) Vortex tubes function by taking a tangentially-introduced higher pressure gas (e.g., compressed air) into a tube's swirl chamber that accelerates the gas to high rate of rotation (see, e.g.,
(13) A controller at the conically-shaped nozzle end may be used to adjust the temperature of the hot and cold air streams, such as to provide a desired cold air stream temperature tailored to the application and operating conditions of interest.
(14) Heat exchanger refers to high thermal efficiency exchangers that provides thermal contact between two fluids of different temperatures. The term is used broadly and includes counter-current, parallel flow, and cross-flow exchangers. In the context of the current invention, the two fluids are a cold air stream and a hydrocarbon containing gas, wherein the heat exchanger inlet temperature of the hydrocarbon containing gas is higher than the inlet temperature of the cold air stream. Accordingly, thermal contact between the cold air stream and the hydrocarbon containing gas stream within the heat exchanger facilitates net heat flow from the hydrocarbon containing stream, thereby lowering the temperature of the hydrocarbon containing gas stream and correspondingly increasing the temperature of the cold air stream to a heated air stream temperature. For wet hydrocarbon containing gas, such a lowering of temperature facilitates condensation of certain hydrocarbon vapors, such as heavier hydrocarbons, into NGL. The NGL is separated from the gas stream and collected leaving a dry hydrocarbon containing gas stream to exit the heat exchanger. For robust heat exchange, the flow path is shaped so as to maximize surface area available for heat exchange, and may be optionally split to provide good thermal contact between the flowstreams. In addition, one or more surfaces may be shared between the fluid conduits, with the hydrocarbon containing gas on one side of the surface and the cold air stream on the opposite side to further increase heat exchange. Any of the conduits may be shaped to enhance heat exchange. Furthermore, heat sinks may be utilized to further control thermal transfer characteristics.
(15) Fluidically connects or fluidically connected refers to two components that are connected such that a fluid is transported between the components while functionality of each component is maintained.
(16) Industrial process refers to a procedure used in the manufacture or isolation of a material. For example, the industrial process may involve chemical or mechanical steps used in a hydrocarbon generation, recovery procedure, or process, such as for a hydrocarbon vapor recovery unit from a hydrocarbon recovery, separation, and/or storage facility.
(17) Mechanically coupling refers to a connection between two components, wherein movement of one component generates movement in another component without affecting the function of the components. The coupling can be direct, such as by a rotating shaft that is attached to two components. Alternatively, the coupling may be indirect such that there is one or more intervening components or materials between two devices, such as a belt, pulley and/or clutch.
(18) BLDT or boundary layer disk turbine, also referred to as a Tesla turbine (see U.S. Pat. No. 1,061,206) or a Prandtl layer turbine (see U.S. Pat. No. 6,174,127), refers to a stack of disks that are spaced apart and rotably mounted on a shaft. In this manner, flow of a fluid between adjacent disks generates disk rotation and corresponding rotation of shaft on which the BLDT is mounted. In this manner, fluid flow over a BLDT can generate energy in the form of a shaft rotation that can be usefully harnessed to control, or at least partially control, an industrial process.
(19) Pressurized drive fluid refers to a drive fluid that is under sufficient pressure at one point compared to another point so as to generate fluid flow between the points. For example, to power a BLDT, the fluid is pressurized upstream of the BLDT compared to downstream of the BLDT, so that fluid flows over the BLDT, thereby providing mechanical rotation of the BLDT.
(20) Compressing refers to increasing the pressure of a gas, such as by introducing additional gas to a fixed volume or by reducing the volume of the gas. Accordingly, compressing may be achieved by one or more of a pump and a compressor. Various compressors may be used to compress gas (referred herein as a compressible gas). Examples of compressors include centrifugal, axial-flow, reciprocating and rotary. Alternatively, a pump may be used to force additional gas into a fixed volume. Compressor pump refers to any component capable of compressing a fluid, such as gas or air.
(21) Mechanical power refers to a device that is powered by mechanical motion arising from flow of fluid over a BLDT. Electrical power, in contrast, refers to a device requiring electricity to function. Chemical power refers to a device that is powered by a chemical process, such as by combustion. Because electrical and/or chemical power requires external input from an energy source, that power is referred to as an external energy source. One advantage of the processes and systems described herein is that the mechanical power can significantly reduce, or avoid altogether a need for external power, but instead leverages an inherent property of the industrial process itself, namely flow of a pressurized fluid (referred herein as a drive fluid). Accordingly, the mechanical power of the present invention is referred to as an internal energy source.
(22) Pneumatic device refers to a device that is mechanically controlled by the use of a pressurized gas. Examples of pneumatic devices useful in a number of industrial processes provided herein include: pressure regulator, pressure sensor, pressure switch, pumps, valves, compressors or actuator.
(23) Closed loop refers to a material, such as a fluid, that is not lost to the environment, but instead is contained within the industrial process and either fed back into the process for re-use or is captured and fed to a collector or an outlet and provided to a sales pipeline.
(24) A compressor that is electric free and gas free refers to a compressor that is capable of solely operating by virtue of the BLDT within the industrial process. In other words, the energy required to power the compressor is internal and no external energy source is required or needed. This results in significant energy savings, including for industrial processes that may be in geographically isolated areas, or in areas where an available external energy source (e.g., the grid), is not readily accessible.
Example 1: Drying a Hydrocarbon-Containing Gas
(25) One example of a process for drying a hydrocarbon-containing gas is provided by the process flow chart of
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(28) The term heat exchanger is used broadly and refers to any device or system that provides cooling of a fluid by another fluid that is of higher temperature. In its most simple form, the heat exchanger may be flow conduits that are in physical contact to provide heat transfer. In such an aspect, the terms inlet and outlet reduce to a position in each conduit wherein there is a substantial heat transfer between the fluids. This can be defined as measurable change in the temperature, such as a change that is at least 1 C., at least 5 C., or a range that is between about 1 C. to 10 C. Accordingly, there are defined two inlets and two outlets, with an inlet/outlet pair for the hydrocarbon stream conduit (150 180) that will be cooled and another inlet/outlet pair for the air stream conduit (140 190) that provides the cooling. A third outlet is provided to remove condensed liquid from a position where liquid condensate locates (e.g., 165 or other convenient location within the conduit defined by 150 and 180 having reduced temperature).
(29) One advantage of the systems and processes provided herein is that they are compatible with other low-energy systems, where minimal externally input energy is required to drive and control the system and simultaneously, revenue-producing product may be generated and collected. Systems provided herein are cost-effective in that efficiencies are realized by avoiding the refrigerant liquids required in conventional cooling systems. Instead, the systems provided herein use compressed air and a vortex tube. In particular, referring to
(30) To keep external energy requirements low or absent, the compressed air may be obtained by incorporating the low-energy systems disclosed in U.S. Pat. Pub. Nos. 2013/0071259 and 2013/0068314, each filed Sep. 14, 2012 specifically incorporated by reference for the air compression, control devices and processes described therein. For example, a boundary layer disk turbine (BLDT) may be used to drive a compressor 90, thereby obtaining compressed air without an external energy power source as further explained in Example 2 and
Example 2: Self-Powered Compressor to Compress Fluids
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(32) In an aspect, the pneumatic control by a BLDT is part of a staged-separation process. For example, referring to
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(35) For simplicity,
(36) Integrating the systems and processes described in Examples 1 and 2 with each other, provides a robust, simple and cost-effective manner for further processing hydrocarbon containing gas without expending additional energy. Accordingly, the systems provided herein are particularly suited for applications where the electrical grid is not readily available and are further advantageous in that there are no or minimal moving components and cooling fluid is readily available from the surrounding ambient air. Accordingly, maintenance and upkeep of the systems are extremely minimal.
(37) Any of the devices and processes described herein further comprise, depending on the application, components known in the art for controlling industrial processes including, valves, regulators, rig-out, sensors (pressure, temperature, flow-rate), conduits or flow lines, piping, containers, containment vessels, separators, filters, mixers. Each application includes corresponding safety devices, valves, primary and secondary pressure and flow controllers and corresponding pressure and flow rates. Each application may vary in configuration or geometry, while maintaining the overall central aspect of the invention, including aspects described as: a pressurized fluid to drive a BLDT that is looped back into the fluid flow at an appropriate location in the process.
(38) All references throughout this application, for example patent documents including issued or granted patents or equivalents; patent application publications; and non-patent literature documents or other source material; are hereby incorporated by reference herein in their entireties, as though individually incorporated by reference, to the extent each reference is at least partially not inconsistent with the disclosure in this application (for example, a reference that is partially inconsistent is incorporated by reference except for the partially inconsistent portion of the reference).
(39) All patents and publications mentioned in the specification are indicative of the levels of skill of those skilled in the art to which the invention pertains. References cited herein are incorporated by reference herein in their entirety to indicate the state of the art, in some cases as of their filing date, and it is intended that this information can be employed herein, if needed, to exclude (for example, to disclaim) specific embodiments that are in the prior art. For example, when a compound is claimed, it should be understood that compounds known in the prior art, including certain compounds disclosed in the references disclosed herein (particularly in referenced patent documents), are not intended to be included in the claim.
(40) When a Markush group or other grouping is used herein, all individual members of the group and all combinations and subcombinations possible of the group are intended to be individually included in the disclosure. Every formulation or combination of components described or exemplified can be used to practice the invention, unless otherwise stated. Whenever a range is given in the specification, for example, a temperature range, a time range, or a pressure range, all intermediate ranges and subranges, as well as all individual values included in the ranges given are intended to be included in the disclosure.
(41) As used herein, comprising is synonymous with including, containing, or characterized by, and is inclusive or open-ended and does not exclude additional, unrecited elements or method steps. As used herein, consisting of excludes any element, step, or ingredient not specified in the claim element. As used herein, consisting essentially of does not exclude materials or steps that do not materially affect the basic and novel characteristics of the claim. Any recitation herein of the term comprising, particularly in a description of components of a composition or in a description of elements of a device, is understood to encompass those compositions and methods consisting essentially of and consisting of the recited components or elements. The invention illustratively described herein suitably may be practiced in the absence of any element or elements, limitation or limitations which is not specifically disclosed herein.