Ethane recovery or ethane rejection operation

• US 10,006,701 B2
• Filed: 01/05/2016
• Issued: 06/26/2018
• Est. Priority Date: 01/05/2016
• Status: Active Grant

• Current Assignee: Fluor Technologies Corporation (Fluor Corporation)
• Original Assignee: Fluor Technologies Corporation (Fluor Corporation)
• Inventors: Mak, John
• Primary Examiner(s): KING, BRIAN M
• Application Number:
  US14/988,388
• Publication Number:
  US 20170191753A1
• Time in Patent Office: 903 Days
• CPC Class Codes: F25J 2200/04 in a dual pressure main column system
• CPC Class Codes: F25J 2200/70 Refluxing the column with a condensed part of the feed stream, i.e. fractionator top is stripped or self-rectified
• CPC Class Codes: F25J 2200/78 Refluxing the column with a liquid stream originating from an upstream or downstream fractionator column
• CPC Class Codes: F25J 2205/04 in the feed line, i.e. upstream of the fractionation step
• CPC Class Codes: F25J 2235/60 the fluid being (a mixture of) hydrocarbons
• CPC Class Codes: F25J 2240/40 Expansion without extracting work, i.e. isenthalpic throttling, e.g. JT valve, regulating valve or venturi, or isentropic nozzle, e.g. Laval
• CPC Class Codes: F25J 2245/02 Recycle of a stream in general, e.g. a by-pass stream
• CPC Class Codes: F25J 2270/90 External refrigeration, e.g. conventional closed-loop mechanical refrigeration unit using Freon or NH3, unspecified external refrigeration
• CPC Class Codes: F25J 2280/02 Control in general, load changes, different modes ("runs"), measurements
• CPC Class Codes: F25J 2290/40 Vertical layout or arrangement of cold equipments within in the cold box, e.g. columns, condensers, heat exchangers etc.
• CPC Class Codes: F25J 3/0209 Natural gas or substitute natural gas
• CPC Class Codes: F25J 3/0233 separation of CnHm with 1 carbon atom or more
• CPC Class Codes: F25J 3/0238 separation of CnHm with 2 carbon atoms or more
• CPC Class Codes: F25J 3/0242 separation of CnHm with 3 carbon atoms or more
• CPC Class Codes: F25J 3/0615 Liquefied natural gas
• CPC Class Codes: F25J 3/064 separation of CnHm with 2 carbon atoms or more
• CPC Class Codes: F25J 3/0695 Start-up or control of the process; Details of the apparatus used

Abstract

A method for operating a natural gas liquids processing (NGL) system, the system being selectively configured in either an ethane rejection configuration or an ethane recovery configuration, the method comprising, when the NGL system is in the ethane rejection configuration, collecting a reboiler bottom stream that, in the ethane rejection configuration, includes ethane in an amount of less than 5% by volume, and when the NGL system is in the ethane recovery configuration, collecting a reboiler bottom stream that, in the ethane recovery configuration, includes ethane in an amount of at least about 30% by volume.

Claims

1. A method for operating a natural gas liquids processing (NGL) system, the system being selectively configured in either an ethane rejection configuration or an ethane recovery configuration, the method comprising:

cooling a feed stream comprising methane, ethane, and propane in a heat exchanger to yield a chilled feed stream;

introducing the chilled feed stream into a separation vessel having a first portion, a second portion, and a third portion, wherein the chilled feed stream is introduced into the first portion of the separation vessel; and

when the NGL system is in the ethane rejection configuration;

heating a bottom stream of the first portion in the heat exchanger to yield a heated bottom stream;

introducing the heated bottom stream into the second portion of the separation vessel;

introducing an overhead stream of the first portion into the third portion of the separation vessel;

introducing a bottom stream of the third portion into the second portion the separation vessel;

heating an overhead stream of the third portion in the heat exchanger, wherein in the ethane rejection configuration the overhead stream of the third portion comprises ethane in an amount of at least about 5% by volume;

introducing a bottom stream of the second portion into a reboiler; and

collecting a reboiler bottom stream, wherein in the ethane rejection configuration the reboiler bottom stream comprises ethane in an amount of less than 5% by volume; and

when the NGL system is in the ethane recovery configuration;

introducing the bottom stream of the first portion into the second portion of the separation vessel;

cooling the overhead stream of the first portion in the heat exchanger to yield a first chilled overhead stream;

introducing the first chilled overhead stream into the third portion of the separation vessel;

introducing the bottom stream of the third portion into the second portion of the separation vessel;

heating the overhead stream of the third portion in the heat exchanger, wherein in the ethane recovery configuration the overhead stream of the third portion comprises ethane in an amount of less than about 10% by volume;

introducing the bottom stream of the second portion into the reboiler; and

collecting the reboiler bottom stream, wherein in the ethane recovery configuration the reboiler bottom stream comprises ethane in an amount of at least about 30% by volume,

wherein the NGL system comprises a first valve, a second valve, a third valve, a fourth valve, a fifth valve, a sixth valve, a seventh valve, and an eighth valve, wherein the first, second, third, fourth, fifth, sixth, seventh, and eighth valves allow particular routes of fluid communication and disallow particular routes of fluid communication so as to configure the NGL system in either the ethane rejection configuration or the ethane recovery configuration.

2. The method of claim 1, wherein the feed stream comprises from about 5 to about 12 gallons of ethane per thousand standard cubic feet of gas in the feed stream.

3. The method of claim 1, wherein the chilled feed stream has a temperature of from about −

15°

F. to about −

45°

F.

4. The method of claim 1, wherein the bottom stream of the first portion is directed, in the ethane rejection configuration, to the heat exchange or in the ethane recovery configuration, to the second portion of the separation vessel via the sixth valve, wherein directing the bottom stream of the first portion through the sixth valve causes a reduction in pressure of the bottom stream to the first portion.

5. The method of claim 1, wherein:

in the ethane rejection configuration, the fourth valve is open, the third valve is closed, and the overhead stream of the first portion is introduced into the third portion of the separation vessel via the fourth valve, and

in the ethane recovery configuration, the third valve is open, the fourth valve is closed, and the overhead stream of the first portion is introduced into the heat exchanger via the third valve.

6. The method of claim 5, wherein directing the overhead stream of the first portion through the fourth valve causes a reduction in pressure of the overhead stream of the first portion.

7. The method of claim 1, wherein:

in the ethane rejection configuration, the seventh valve is closed and the eighth valve is open, and

in the ethane recovery configuration, the seventh valve is open, the eighth valve is closed, and the first portion bottom stream is introduced into the second portion of the separation vessel via the seventh valve.

8. The method of claim 1, further comprising:

when the NGL system is in the ethane rejection configuration;

cooling an overhead stream of the second portion in the heat exchanger to yield a second chilled overhead stream; and

introducing the second chilled overhead stream into the third portion of the separation vessel; and

when the NGL system is in the ethane recovery configuration;

introducing the overhead stream of the second portion into the third portion of the separation vessel.

9. The method of claim 8, wherein:

in the ethane rejection configuration, the first valve is closed, the second valve is open, and the overhead stream of the second portion is introduced into the heat exchanger via the second valve, and

in the ethane recovery configuration, the first valve is open, the second valve is closed, and the overhead stream of the second portion is introduced into the third portion of the separation vessel via the first valve.

10. The method of claim 8, wherein the second chilled overhead stream is introduced into the third portion of the separation vessel via the fifth valve, wherein directing the second chilled overhead stream through the fifth valve causes a reduction in pressure of the second chilled overhead stream.

11. The method of claim 1, further comprising, in both the ethane rejection configuration and the ethane recovery configuration, returning a reboiler overhead stream to the second portion of the separation vessel.

12. A natural gas processing (NGL) system, the NGL system being selectively configured in either an ethane rejection configuration or an ethane recovery configuration, the NGL system comprising:

a heat exchanger;

a separation vessel having a first portion, a second portion, and a third portion; and

a reboiler,

wherein the NGL system is configured to;

cool a feed stream comprising methane, ethane, and propane in the heat exchanger to yield a chilled feed stream;

introduce the chilled feed stream into the first portion of the separation vessel; and

when the NGL system is in the ethane rejection configuration, the NGL system is further configured to;

heat a bottom stream of the first portion in the heat exchanger to yield a heated bottom stream;

introduce the heated bottom stream into the second portion of the separation vessel;

introduce an overhead stream of the first portion into the third portion of the separation vessel;

introduce a bottom stream of the third portion into the second portion of the separation vessel;

heat an overhead stream of the third portion in the heat exchanger, wherein in the ethane rejection configuration the third portion overhead stream comprises ethane in an amount of at least 5% by volume;

introduce a bottom stream of the second portion into the reboiler; and

collect a reboiler bottom stream, wherein in the ethane rejection configuration the reboiler bottom stream comprises ethane in an amount of less than 5% by volume; and

when the NGL system is in the ethane recovery configuration, the NGL system is further configured to;

introduce the bottom stream of the first portion into the second portion of the separation vessel;

cool the overhead stream of the first portion in the heat exchanger to yield a first chilled overhead stream;

introduce the first chilled overhead stream into the third portion of the separation vessel;

introduce the bottom stream of the third portion into the second portion the separation vessel;

heat the overhead stream of the third portion in the heat exchanger, wherein in the ethane recovery configuration the third portion overhead stream comprises ethane in an amount of less than 10% by volume;

introduce the bottom stream of the second portion into the reboiler; and

collect the reboiler bottom stream, wherein in the ethane recovery configuration the reboiler bottom stream comprises ethane in an amount of at least 30% by volume,

wherein the NGL system further comprises a first valve, a second valve, a third valve, a fourth valve, a fifth valve, a sixth valve, a seventh valve, and an eighth valve, wherein the first, second, third, fourth, fifth, sixth, seventh, and eighth valves allow particular routes of fluid communication and to disallow particular routes of fluid communication so as to configure the NGL system in either the ethane rejection configuration or the ethane recovery configuration.

13. The system of claim 12, wherein the NGL system is further configured such that the bottom stream of the first portion is directed, in the ethane rejection configuration, to the heat exchanger or, in the ethane recovery configuration, to the second portion of the separation vessel via the sixth valve, wherein directing the bottom stream of the first portion through the sixth valve causes a reduction in pressure of the bottom stream of the first portion.

14. The system of claim 12, wherein the NGL system is further configured such that:

in the ethane rejection configuration, the fourth valve is open, the third valve is closed, and the overhead stream of the first portion is introduced into the third portion of the separation vessel via the fourth valve, and

in the ethane recovery configuration, the third valve is open, the fourth valve is closed, and the overhead stream of the first portion is introduced into the heat exchanger via the third valve.

15. The system of claim 14, wherein the NGL system is further configured such that directing the overhead stream of the first portion through the fourth valve causes a reduction in pressure of the overhead stream of the first portion.

16. The system of claim 12, wherein the NGL system is further configured such that:

in the ethane rejection configuration, the seventh valve is closed and the eighth valve is open, and

in the ethane recovery configuration, the seventh valve is open, the eighth valve is closed, and the bottom stream of the first portion is introduced into the second portion of the separation vessel via the seventh valve.

17. The system of claim 12, wherein:

when the NGL system is in the ethane rejection configuration, the NGL system is further configured to;

cool an overhead stream of the second portion in the heat exchanger to yield a second chilled overhead stream; and

introduce the second chilled overhead stream into the third portion of the separation vessel; and

when the NGL system is in the ethane recovery configuration, the NGL system is further configured to;

introduce the overhead stream of the second portion to the third portion of the separation vessel.

18. The system of claim 17, wherein the NGL system is further configured such that:

in the ethane rejection configuration, the first valve is closed, the second valve is open, and the overhead stream of the second portion is introduced into the heat exchanger via the second valve, and

in the ethane recovery configuration, the first valve is open, the second valve is closed, and the overhead stream of the second portion is introduced into the third portion of the separation vessel via the first valve.

19. The system of claim 17, wherein the NGL system is further configured such that the second chilled overhead stream is introduced into the third portion of the separation vessel via the fifth valve, wherein directing the second chilled overhead stream through the fifth valve causes a reduction in pressure of the second chilled overhead stream.

20. The system of claim 12, wherein in both the ethane rejection configuration and the ethane recovery configuration, the NGL system is further configured to return a reboiler overhead stream to the second portion of the separation vessel.

21. A method for processing gas, comprising:

feeding a feed gas stream comprising methane, ethane, and C3+ compounds to an integrated separation column, wherein the integrated separation column is selectably configurable between an ethane rejection configuration and an ethane recovery configuration;

operating the integrated separation column in the ethane rejection configuration, wherein the feed gas stream is cooled and subsequently flashed in a bottom isolated portion of the integrated separation column to form a flash vapor, wherein the flash vapor is reduced pressure and subsequently fed as a vapor to an upper isolated portion of the integrated separation column;

wherein an overhead stream from an intermediate isolated portion of the integrated separation column is cooled and fed as a liquid to the upper isolated portion of the integrated separation column;

recovering an overhead residual gas stream comprising methane and ethane from the integrated separation column, wherein the overhead residual gas stream comprises equal to or greater than 40 volume percent of the ethane in the feed gas stream;

recovering a bottom natural gas liquid (NGL ) product stream comprising ethane and C3+ compounds from the integrated separation column;

discontinuing operation of the integrated separation column in the ethane rejection configuration;

reconfiguring the integrated separation column from the ethane rejection configuration to the ethane recovery configuration;

operating the integrated separation column in the ethane rejection configuration, wherein the feed gas stream is cooled and subsequently flashed in the bottom isolated portion of the integrated separation column to form the flash vapor, wherein the flash vapor is cooled and subsequently fed as a liquid to an upper isolated portion of the integrated separation column;

wherein the overhead stream from the intermediate isolated portion of the integrated separation column is fed as the vapor to the upper isolated portion of the integrated separation column;

recovering the overhead residual gas stream comprising methane and ethane from the integrated separation column; and

recovering the bottom natural gas liquid (NGL) product stream comprising ethane and C3+ compounds from the integrated separation column, wherein the overhead residual gas stream comprises equal to or greater than 95 volume percent o f the ethane in the feed gas stream.