Multi nitrogen expansion process for LNG production

Abstract

A method of natural gas liquefaction includes at least two nitrogen refrigerant streams. Each stream undergoes a cycle of compression, cooling, expansion and heating, during which each of the nitrogen streams is expanded to a different pressure other than for the others of the at least two nitrogen streams, and, the heating occurs in one or more heat exchangers. The expanded nitrogen streams are in a heat exchanging relationship with a stream of the natural gas and with the one or more compressed nitrogen streams in at least one of the one or more heat exchangers. At least one expanded nitrogen stream is compressed as a side stream in a stage of a main nitrogen compressor so as to combine the compressed side stream with another compressed nitrogen stream after passing the nitrogen compressor stage.

Claims

1. A method of natural gas liquefaction comprising at least two nitrogen refrigerant streams, each of said at least two nitrogen streams undergoing a cycle of compression, cooling, expansion and heating, during which each of the at least two nitrogen streams is expanded to a different pressure than the others of the at least two nitrogen streams, and, the heating occurs in one or more heat exchangers; the at least two expanded nitrogen streams being in a heat exchanging relationship with a stream of the natural gas and with the at least two compressed nitrogen streams in at least one of said one or more heat exchangers, wherein at least one of said at least two expanded nitrogen streams, after having been in said heat exchanging relationship in the at least one of the one or more heat exchangers, is compressed as a side stream in a stage of a main nitrogen compressor comprising at least two compressor stages, a first compressor stage (22) and a second compressor stage (23), and wherein an outlet of the first compressor stage (22) is coupled to an inlet of the second compressor stage (23) in such a way that a compressor outlet stream from a low pressure turbo expander (L) after being pressurized in the first compressor stage (22) is added to a compressor outlet stream from a high pressure turbo expander (H) before the inlet of the second compressor stage (23) so as to combine the compressed side stream with another compressed nitrogen stream after passing said nitrogen compressor stage.

2. The method according to claim 1, wherein the main nitrogen compressor comprises at least two compressors coupled on a common drive shaft.

3. The method according to claim 1, wherein a compressed nitrogen stream from the compressor stages is divided over at least two parallel placed expanders to different pressure levels.

4. The method according to claim 3, wherein each expander is connected over a common drive shaft to a compressor for compressing a nitrogen flow.

5. The method according to claim 1, wherein the main nitrogen compressor is gas turbine driven or electric motor driven or steam turbine driven.

6. The method according to claim 1, wherein the expansion comprises a high pressure, an intermediate pressure and a low pressure expansion stage in a respective expander.

7. The method according to claim 1, wherein the main nitrogen compressor comprises three compressor stages and receives two side streams with different pressures.

8. The method according to claim 7, wherein the three compressors are coupled on a common drive shaft.

9. The method according to claim 1, wherein a third expander which is a Joule-Thompson valve is placed parallel with said low pressure and high pressure turbo expanders.

10. A natural gas liquefaction apparatus comprising a heat exchanger system of one or more heat exchangers for placing the natural gas in a heat exchanging relationship with multiple nitrogen refrigerant streams; at least two compressors for compressing a first and an at least second nitrogen refrigerant stream; a first turbo expander comprising a first expander for expanding the first nitrogen stream to a first pressure, and at least a second turbo expander comprising a second expander for expanding the at least second nitrogen stream to an at least second, lower pressure than the first pressure, wherein the apparatus further comprises a main nitrogen compressor with at least two compressor stages, each compressor stage being arranged for receiving an associated nitrogen stream, wherein an outlet of a first compressor stage (22) is coupled to an inlet of a second compressor stage (23) in such a way that a compressor outlet stream from the low pressure turbo expander (L) after being pressurized in the first compressor stage (22) is added to a compressor outlet stream from the high pressure turbo expander (H) before the inlet of the second compressor stage (23) and wherein each nitrogen stream has a different pressure other than the other of the at least two nitrogen streams, one nitrogen stream being a side stream which will be combined with the other nitrogen stream.

11. The apparatus according to claim 10, wherein the one nitrogen stream is combined with the other nitrogen stream after passing the first compressor stage and before entry of the other nitrogen stream into the second compressor stage.

12. The apparatus according to claim 10, wherein the main nitrogen compressor comprises at least two compressors coupled on a common drive shaft.

13. The apparatus according to claim 10, wherein the compressed nitrogen stream from the main nitrogen compressor is divided over at least two parallel placed expanders to different pressure levels.

14. The apparatus according to claim 12, wherein each expander is connected over a common drive shaft to a compressor arranged for compressing a nitrogen flow.

15. The apparatus according to claim 14, wherein at least one compressor receives and compresses at least a part of the nitrogen stream that passed the heat exchanger system before said part of the nitrogen stream flows to the main nitrogen compressor.

16. The apparatus according to claim 11, wherein the main nitrogen compressor unit is gas turbine driven or electric motor driven or steam turbine driven.

17. The apparatus according to claim 11, wherein the first and at least second expander comprise a high pressure, an intermediate pressure and a low pressure expansion stage in a respective expander.

18. The apparatus according to claim 11, wherein the main nitrogen compressor comprises three compressors and receives two side streams with different pressures.

19. The apparatus according to claim 18, comprising a third expander placed parallel with said first and second turbo expander, wherein said third expander is a Joule-Thompson valve.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The invention will be further described below in connection with exemplary embodiments with reference to the accompanying drawings, wherein

(2) FIG. 1 shows a prior art dual nitrogen expander process of Statoil;

(3) FIG. 2 shows an dual expansion process according to an embodiment of the invention;

(4) FIG. 3 shows another dual expansion process according to an embodiment of the invention;

(5) FIG. 4 shows a first triple expansion process scheme according to an embodiment of the invention;

(6) FIG. 5 shows an alternative triple expansion process scheme according to an embodiment of the invention;

(7) FIG. 6 shows a dual expansion process according to an embodiment of the invention with a Joule-Thompson (JT) valve for HP expansion stage;

(8) FIG. 7 shows an alternative dual expansion process according to an embodiment of the invention with a JT valve for HP expansion stage.

DESCRIPTION OF EMBODIMENTS

(9) FIG. 1 shows a prior art system for a dual nitrogen expander process of Statoil for the liquefaction of natural gas.

(10) The process system 100 according to the prior art comprises a heat exchanger system 2, i.e. one or more heat exchangers or heat sinks or cold boxes, a first (turbo) expander unit 3, a second turbo expander unit 4, and cycle compressor(s) 5, 6. Further, the process facility comprises inter-coolers and after-coolers 7, 8, 9.

(11) The process system 100 comprises an inlet for natural feed gas 10. The natural feed gas passes as a natural gas stream 15 through the heat exchanger system 2 towards a flash device 11 which separates liquid natural gas (LNG) from residual gas (flash gas). Within the heat exchanger system 2 the stream of natural feed gas is cooled by a counter flow 17, 19 of cold nitrogen gas. The cold nitrogen counter flow is generated in the first and second expanders 3b, 4b. At the outlet of the heat exchanger system the warm nitrogen is sent to the main cycle compressor 5, 6. that produce a high pressure stream 18 of nitrogen. After the high pressure stream has passed the compressors 3a, 4a of the first and second turbo expanders 3, 4, the nitrogen stream continues as a high pressure nitrogen stream 16. The high pressure stream 16 enters the heat exchanger 2 and flows parallel to the natural feed gas stream 15 towards the expander parts 3b, 4b of the turbo expanders 3, 4. After passing the expander parts, the nitrogen stream has cooled further and continues as the counter flow 17 in the heat exchanger system 2. With reference to FIG. 1; the nitrogen expander concept has already been enhanced in terms of efficiency by moving from a single pressure level cycle with one expander, to dual pressure levels with 2 expanders.

(12) FIG. 2 shows an alternative process scheme 54 according to an embodiment of the invention. In this embodiment, the expansion of the nitrogen gas cycle is handled by two turbo expanders H, L.

(13) One turbo expander L is arranged for a relatively low pressure expansion of the nitrogen gas, the other turbo expander H is arranged for a relatively high pressure expansion.

(14) The main nitrogen compressor in this embodiment comprises two coupled compressor stages or units 22, 23. A first compressor stage 22 has an inlet coupled to the outlet of the compressor part LC of the low pressure turbo expander L. The stream feeding the first compressor 22 is coming from the compressor part LC.

(15) A second compressor stage 23 has an inlet stream coming from the outlet of the compressor part HC of the high pressure turbo expander H.

(16) The outlet of the first compressor stage is coupled to the inlet of the second compressor stage in such a way that the compressor outlet stream from the low pressure turbo expander L after being pressurized in the first compressor stage is added to the compressor outlet stream from the high pressure turbo expander before the inlet of the second compressor stage.

(17) In this manner a high pressure compressed stream CS is formed that enters the heat exchanger system 2 in a flow parallel to the natural feed gas 15.

(18) Within the heat exchanger system the high pressure compressed stream CS is split to a first entry stream for the high pressure expander HE and a second entry stream for the low pressure expander LE.

(19) In each of the turbo expanders the respective entry stream is expanded as a cooled nitrogen stream HS; LS that is transported through the heat exchanger system 2 in a counter flow relative to the natural feed gas stream and the high pressure compressed nitrogen stream CS. After passing the heat exchanger system 2 each of the cooled nitrogen streams HS, LS is directed to the inlet of the respective compressor HC; LC. Thus, the cooled nitrogen stream LS from the low pressure turbo expander L is transported through the heat exchanger 2 and then directed to the inlet of the compressor part LC of the low pressure turbo expander. The cooled nitrogen stream HS from the high pressure turbo expander H is transported through the heat exchanger system and then directed to the inlet of the compressor part HC of the high pressure turbo expander.

(20) Intercoolers/aftercoolers are installed: an intercooler 36 is installed between the compressor outlet of the high pressure turbo expander H and the inlet of the second compressor stage 23. A second intercooler 32 is installed between the outlet of the first compressor stage 22 and the inlet of the second compressor stage 23. A third intercooler 35 is installed at the outlet of the second compressor stage.

(21) It is noted that the single heat exchanger 2 may be embodied as a number of heat exchanger units, for example plate-fin type heat exchanger, spiral wound type heat exchanger of shell-and-tube type heat exchanger.

(22) FIG. 3 shows another alternative processing scheme 55 according to an embodiment of the invention. Like the embodiment as shown in FIG. 2, the process scheme applies an expansion of the nitrogen gas cycle handled by two turbo expanders H, L, and a dual stage main nitrogen compressor.

(23) In this embodiment however, the high pressure stream CS produced by the main nitrogen compressor is not transported directly to the heat exchanger but first transported through the compressor parts HC; LC of the high pressure turbo expander and the low pressure turbo expander, respectively. The high pressure stream DS from the main nitrogen compressor is split in a stream to the compressor part HC of the high pressure turbo expander and a stream to the compressor part LC of the low pressure turbo expander. After passing the respective compressor parts, the streams are combined into a single stream that passes the heat exchanger in a flow parallel to the natural feed gas stream.

(24) In or at the heat exchanger 2 the compressed stream CS is split into a stream to the inlet of the high pressure expander HE and a stream to the inlet of the low pressure expander LE. Each of the streams after expansion cooling in the respective expander part HE; LE is transported through the heat exchanger 2 and then transported to the corresponding compressor stages 22; 23 of the main nitrogen compressor: the stream from the low pressure turbo expander L to the inlet of the first compressor stage 22, the stream from the high pressure turbo expander H to the inlet of the second compressor stage 23. The pressurized stream from the first compressor stage is joined with the stream for entering the inlet of the second compressor stage.

(25) Intercoolers 32; 33 are arranged to cool the streams after compressing.

(26) FIG. 4 shows a first triple expansion process scheme 50 according to an embodiment of the invention.

(27) The liquefaction process can be further improved by adding a third pressure level, and a third expansion step. In this configuration four pressure levels would exist for the circulation of nitrogen streamshigh pressure from the compressor discharge, two intermediate pressures, and low pressure.

(28) HP (high pressure) nitrogen would be cooled in the cold box, and the first extraction stream would feed the HP expander HE, generating a cold N2 stream which is fed back into the heat exchanger system, and returns to the third stage suction of the main nitrogen compressor 22, 23, 24.

(29) More cooled HP nitrogen is taken in a second extraction stream to feed the IP (intermediate pressure) expander IE, generating a second cold N2 stream which is fed back into the heat exchanger system, and returns to the second stage suction of the main nitrogen compressor.

(30) The remaining sub-cooled HP nitrogen is taken in a third extraction stream to feed the LP (low pressure) expander LE, generating a third cold N2 stream which is fed back into the heat exchanger system, and returns to the first stage suction of the main nitrogen compressor.

(31) Compressed nitrogen from the third stage compressor discharge is further boosted in pressure using the compressors HC, IC, LC coupled to the three expanders HE, IE, LE respectively. Each compressor is coupled to a respective expander over a common drive shaft.

(32) In this way, three levels of chilling are produced, and at the same time, since all return flows from the heat exchanger system are coupled to the main nitrogen compressor, the main nitrogen gas compressor power is minimized, hence improving the overall efficiency of the LNG production process.

(33) In addition, the three temperature levels created by the respective expanders provide a cooling curve in the heat exchanger system which has improved efficiency.

(34) This is illustrated in more detail with reference to FIG. 4.

(35) As shown in FIG. 4, three pressure levels are present in the turbo expanders, which comprise a high pressure level turbo expander H, an intermediate pressure turbo expander I and a low pressure turbo expander L. Each turbo expander comprises an expander part HE, IE, LE and a compressor part HC; IC; LC, in which the drive shaft of the expander part is coupled with the drive shaft of the compressor part. The outlet for expanded nitrogen for each expander HE; IE; LE is coupled to the heat exchanger system 2 for transfer of cold expanded nitrogen in a high pressure stream HS, an intermediate pressure stream IS and a low pressure stream LS, respectively, through the heat exchanger.

(36) Further the cycle compressor arrangement is made of three nitrogen compressor stages 22, 23, 24 that are arranged for compressing the respective expanded nitrogen gas streams from each of the expanded nitrogen streams HS, IS, LS into a single compressed stream CS. At the outlet of each compressor stage an intercooler 32, 33, 34 is arranged for cooling the compressed nitrogen stream.

(37) The compressed stream CS is arranged to pass the compressor side HC; IC; LC for driving each one of the high pressure turbo expander H, intermediate pressure turbo expander I and low pressure turbo expander L. After delivery of kinetic energy to the turbo expanders the compressed stream CS is cooled by an intercooler 35 and then transported through the heat exchanger 2, in a stream parallel to the natural feed gas stream. The compressed stream CS is cooled during passage through the heat exchanger.

(38) Within the heat exchanger system or at the entry therein, the compressed stream is distributed over separate streams to each of the high pressure expander HE, intermediate pressure expander IE and low pressure expander LE as feed for the nitrogen gas to be expanded in each respective expander HE; IE; LE at a high, intermediate and low pressure level, respectively.

(39) The main nitrogen compressor assembly (coupled nitrogen compressor stages) is driven by a compressor driver GT, which in an embodiment is gas-turbine, coupled by a drive shaft to the main nitrogen compressor. In an alternative embodiment, the compressor driver GT may be a motor such as an electric motor or a steam turbine.

(40) FIG. 5 shows an alternative triple expansion process scheme 51 according to an embodiment of the invention

(41) Within FIG. 5 exemplary pressure levels (in bars) and flow rates (% of total flow) are displayed. The values presented here are only indicative and are not intended to limit the invention.

(42) In this alternative embodiment (FIG. 5), the compressors HC; IC; LC coupled to the respective HP, IP and LP expanders HE, IE, LE are used to boost the pressure of the HP, IP and LP gas respectively, before the streams are sent to the third 24, second 23 and first 22 stages of the main nitrogen compressor, respectively. In each stream at the outlet of the compressor part of the main nitrogen compressor 22, 23, 24 an intercooler 32; 33; 34 is arranged for cooling the respective compressed stream.

(43) In an exemplary embodiment, the compressed stream CS before entry of the heat exchanger is a full flow (100%) of nitrogen at a pressure of about 65 bar (1 bar 1 atm). In the heat exchanger the compressed stream is split in a high pressure stream HS (33% flow, 29.8 bar), an intermediate stream IS (40%, 17.1 bar) and a low pressure stream LS (27%, 12 bar).

(44) After expanding each stream in the high pressure expander part HE, the intermediate pressure expander part IE and the low pressure expander part LE, respectively, the respective stream is fed to the heat exchanger system 2 and after passing the heat exchanger to the respective compressor part HC; IC; LC.

(45) In the example, the low pressure stream LS is boosted to 16.5 bar and entered into the first nitrogen compressor stage 22 of the main nitrogen compressor; the intermediate pressure stream IS to 28 bar and entered into the second nitrogen compressor stage 23; and the high pressure stream to about 43.4 bar and entered into the third nitrogen compressor stage 24.

(46) FIG. 6 shows a dual expansion process scheme 52 according to an embodiment of the invention with a Joule-Thompson (JT) valve for HP expansion stage.

(47) In this alternative embodiment (FIG. 6), that is arranged with a similar nitrogen feed scheme as the embodiment described with reference to FIG. 4, instead of the HP turbo-expander a Joule Thompson (JT) expansion valve is arranged in the high pressure stream. The HP turbo expander has been replaced with the Joule-Thompson (JT) expansion valve, and the HP compressor is deleted. After passing the heat exchanger 2, the high pressure stream is now directly fed to the third nitrogen compressor stage 24 of the main nitrogen compressor.

(48) This embodiment may allow a simpler way of generating three pressure levels of chilling, but will be less efficient than the process shown in FIGS. 4 and 5.

(49) In FIG. 7 a yet another alternative embodiment 53 is shown in which the simpler JT valve process from FIG. 6 is combined with the alternative compressor configuration of FIG. 5 to give an alterative scheme for a triple expansion process.

(50) The efficiency of the entire process scheme may be further improved by the addition of a pre-cooling stage using a refrigerant loop or any other refrigeration means, in order to reduce the inlet temperature of the process gas before entering the cold box, or by adding an additional refrigeration cycle to cool down the intercoolers and/or aftercoolers of the compressors.

(51) Although particular embodiments of the invention have been described and illustrated herein, it is recognized that modifications and variations may readily occur to those skilled in the art, and consequently, it is intended that the claims be interpreted to cover such modifications and equivalents.