Method and apparatus for removing benzene contaminants from natural gas

• US 10,126,049 B2
• Filed: 02/19/2016
• Issued: 11/13/2018
• Est. Priority Date: 02/24/2015
• Status: Active Grant

• Current Assignee: Ihi Energy Solutions, Inc.
• Original Assignee: IHI E&C International Corporation (IHI Corporation)
• Inventors: Shah, Kamal
• Primary Examiner(s): King, Brian
• Application Number:
  US15/048,291
• Publication Number:
  US 20160245587A1
• Time in Patent Office: 998 Days
• CPC Class Codes: C10L 3/10 Working-up natural gas or synthetic natural gas
• CPC Class Codes: C10L 3/101 Removal of contaminants
• CPC Class Codes: F25J 2200/02 in a single 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 2200/74 Refluxing the column with at least a part of the partially condensed overhead gas
• CPC Class Codes: F25J 2205/04 in the feed line, i.e. upstream of the fractionation step
• CPC Class Codes: F25J 2205/50 using absorption, i.e. with selective solvents or lean oil, heavier CnHm and including generally a regeneration step for the solvent or lean oil
• CPC Class Codes: F25J 2210/04 Mixing or blending of fluids with the feed stream
• CPC Class Codes: F25J 2220/60 Separating impurities from natural gas, e.g. mercury, cyclic hydrocarbons
• CPC Class Codes: F25J 2240/02 Expansion of a process fluid in a work-extracting turbine (i.e. isentropic expansion), e.g. of the feed stream
• CPC Class Codes: F25J 2245/02 Recycle of a stream in general, e.g. a by-pass stream
• 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 3/0247 separation of CnHm with 4 carbon atoms or more

Abstract

A method and apparatus for removing benzene from a lean natural gas feed is provided. The method and apparatus are capable of removing benzene from lean natural gas that is predominantly composed of methane and contains very little heavier hydrocarbon components.

Claims

1. A method for removing benzene from a lean natural gas feed containing benzene, the method comprising:

splitting a dehydrated feed gas into a first input stream directed into a rich/lean gas exchanger to provide a first output stream and a second input stream directed into a demethanizer side re-boiler to provide a second output stream;

feeding the first output stream from the rich/lean gas exchanger into a expander suction drum;

feeding the second output stream into the expander suction drum;

splitting a gaseous output stream from the expander suction drum into a first expander suction drum output stream, a second expander suction drum output stream, and a third expander suction drum condensate output stream;

feeding the first expander suction drum output stream into a demethanizer column reflux exchanger to produce an exchanged gas stream and feeding the exchanged gas stream into a demethanizer column;

feeding the second expander output stream into a gas expander to produce an expanded gas and feeding the expanded gas into the demethanizer column;

feeding the third expander suction drum condensate output stream into the demethanizer column;

condensing the exchanged gas stream and the expanded gas in the demethanizer column to form a NGL (natural gas liquid) condensate;

feeding the NGL condensate from a bottom of the demethanizer column into a stabilizer inlet cooler and subsequently into a stabilizer;

directing a gas stream from the stabilizer into a stabilizer condenser to provide a first condensate;

feeding the first condensate into a stabilizer reflux drum to form a first stabilized condensate;

providing a solvent makeup stream comprising a formulated hydrocarbon based solution containing a majority of hydrocarbon components lighter than hexane and heavier than butane;

providing a solvent storage tank for the formulated hydrocarbon based solution;

pumping the formulated hydrocarbon based solution with one or more solvent make up pumps into a liquid stream comprising the first stabilized condensate to form a combined liquid stream;

feeding the combined liquid stream into one or more NGL reinjection pumps, solvent recycle pumps, or a combination thereof to form a solvent recycle stream; and

feeding the solvent recycle stream back into the dehydrated gas feed.

2. The method of claim 1, wherein the formulated hydrocarbon based solution contains between 50% and 99% by weight of hydrocarbons lighter than hexane and heavier than butane.

3. The method of claim 1, wherein a total amount of C₂ plus, C₃ plus, and/or C₄ plus components in the lean natural gas feed is between 1000 ppm and 1 ppm.

4. The method of claim 1 further comprising outputting a lean gas stream from an overhead of the demethanizer, wherein the lean gas stream contains from less than 1 ppm of benzene to 0.001 ppm of benzene.

5. An apparatus for removing benzene from a natural gas feed containing benzene, comprising:

a rich/lean gas exchanger configured for receiving a first input stream from the natural gas feed and producing a first output stream;

a demethanizer side re-boiler configured for receiving a second input stream from the natural gas feed and producing a second output stream;

an expander suction drum configured for receiving the first and second output streams and producing a gaseous output stream comprising at least a first expander suction drum output stream;

a demethanizer reflux exchanger configured for receiving the first expander suction drum output stream from the expander suction drum and producing an exchanged gas stream;

a demethanizer unit configured for receiving the exchanged gas stream from the demethanizer reflux exchanger and condensing the exchanged gas stream to form a first NGL condensate stream;

a stabilizer inlet cooler configured for receiving the first NGL condensate stream from the demethanizer unit and producing a liquid feed stream;

a stabilizer configured for receiving the liquid feed stream from the stabilizer inlet cooler and producing a gas stream;

a stabilizer condenser configured for receiving the gas stream from the stabilizer and producing a first condensate;

a stabilizer reflux drum configured for receiving the first condensate from the stabilizer condenser and producing a first stabilized condensate;

a solvent storage tank configured for storing a formulated hydrocarbon based solution containing a majority of hydrocarbon components lighter than hexane and heavier than butane;

a plurality of solvent makeup pumps configured for pumping the formulated hydrocarbon based solution into a liquid stream comprising the first stabilized condensate to form a combined liquid stream; and

a plurality of NGL reinjection pumps, solvent recycle pumps, or a combination thereof configured for receiving the combined liquid stream from the plurality of solvent makeup pumps and forming a solvent recycle stream.

6. The apparatus of claim 5, wherein the formulated hydrocarbon based solution contains between 50% and 99% by weight of hydrocarbons lighter than hexane and heavier than butane.

7. The apparatus of claim 5, wherein a total amount of C₂ plus, C₃ plus, and/or C₄ plus components in the natural gas feed is between 1000 ppm and 1 ppm.

8. The apparatus of claim 5, wherein the demethanizer unit comprises an overhead and is configured for outputting a lean gas stream from the overhead, wherein the lean gas stream contains from less than 1 ppm of benzene to 0.001 ppm of benzene.