Natural gas liquefaction employing independent refrigerant path

• US 10,655,911 B2
• Filed: 06/20/2012
• Issued: 05/19/2020
• Est. Priority Date: 06/20/2012
• Status: Active Grant

• Current Assignee: Battelle Energy Alliance LLC (Battelle Memorial Institute)
• Original Assignee: Battelle Energy Alliance LLC (Battelle Memorial Institute)
• Inventors: Turner, Terry D., Wilding, Bruce M., McKellar, Michael G., Bingham, Dennis N., Klingler, Kerry M.
• Primary Examiner(s): Raymond, Keith M
• Assistant Examiner(s): Mengesha, Webeshet
• Application Number:
  US13/528,246
• Publication Number:
  US 20130340475A1
• Time in Patent Office: 2,890 Days
• Field of Search: 62611, 62612, 62614
• CPC Class Codes: F25J 1/0022 Hydrocarbons, e.g. natural gas
• CPC Class Codes: F25J 1/004 by flash gas recovery F25J1/0267 takes precedence
• CPC Class Codes: F25J 1/0042 by liquid expansion with extraction of work
• CPC Class Codes: F25J 1/0045 by vaporising a liquid return stream
• CPC Class Codes: F25J 1/005 by expansion of a gaseous refrigerant stream with extraction of work
• CPC Class Codes: F25J 1/0052 by vaporising a liquid refrigerant stream
• CPC Class Codes: F25J 1/0204 as a single flow SCR cycle
• CPC Class Codes: F25J 1/0208 in combination with an internal quasi-closed refrigeration loop, e.g. with deep flash recycle loop F25J1/021 takes precedence
• CPC Class Codes: F25J 1/0212 as a single flow MCR cycle
• CPC Class Codes: F25J 1/0219 in combination with an internal quasi-closed refrigeration loop, e.g. using a deep flash recycle loop
• CPC Class Codes: F25J 1/025 Details related to the refrigerant production or treatment, e.g. make-up supply from feed gas itself
• CPC Class Codes: F25J 2205/10 using combined expansion and separation, e.g. in a vortex tube, "Ranque tube" or a "cyclonic fluid separator", i.e. combination of an isentropic nozzle and a cyclonic separator; Centrifugal separation
• CPC Class Codes: F25J 2205/20 using solidification of components
• CPC Class Codes: F25J 2205/84 using filter
• CPC Class Codes: F25J 2210/06 Splitting of the feed stream, e.g. for treating or cooling in different ways
• CPC Class Codes: F25J 2220/66 Separating acid gases, e.g. CO2, SO2, H2S or RSH
• CPC Class Codes: F25J 2235/60 the fluid being (a mixture of) hydrocarbons

Abstract

A method of liquefying natural gas. The method comprises cooling a gaseous natural gas process stream with a refrigerant flowing in a path isolated from the natural gas process stream. The refrigerant may differ in composition from a composition of the natural gas process stream, and the refrigerant composition may be selected to enhance efficiency of the refrigerant path with regard to a specific composition of the natural gas process stream. The refrigeration path may be operated at pressures, temperatures and flow rates differing from those of the natural gas process stream. Other methods of liquefying natural gas are described. A natural gas liquefaction plant is also described.

Claims

1. A method of liquefying natural gas, the method comprising:

cooling a compressed gaseous refrigerant stream of a refrigerant loop in a channel of a heat exchanger to form a partially gaseous refrigerant stream comprising a gaseous phase and a liquid phase;

separating the gaseous phase from the liquid phase in a separation vessel downstream of the channel of the heat exchanger to form a gaseous refrigerant side stream and a liquid refrigerant stream;

expanding the gaseous refrigerant side stream in an expansion device downstream of the separation vessel;

combining the expanded, gaseous refrigerant side stream with the liquid refrigerant stream in a mixer downstream of the expansion device to form another partially gaseous refrigerant stream; and

directing the another partially gaseous refrigerant stream into another channel of the heat exchanger downstream of the mixer prior to modifying a temperature of the another partially gaseous refrigerant stream to extract heat from a natural gas process stream of a natural gas processing path fluidly separate from the refrigerant loop to liquefy at least a portion of the natural gas process stream and form a gaseous refrigerant stream.

2. The method of claim 1, further comprising forming the compressed gaseous refrigerant stream of the refrigerant loop to exhibit the same material composition the natural gas process stream of the natural gas processing path.

3. The method of claim 2, further comprising maintaining at least one of different pressures, temperatures and flow rates in the refrigerant loop and the natural gas processing path.

4. The method of claim 1, further comprising forming the compressed gaseous refrigerant stream of the refrigerant loop to exhibit a different material composition than the natural gas process stream of the natural gas processing path, the compressed gaseous refrigerant stream comprising at least one of methane, ethane, and propane.

5. The method of claim 4, further comprising selecting the compressed gaseous refrigerant stream to be devoid of CO₂.

6. The method of claim 1, wherein expanding the gaseous refrigerant side stream in the expansion device downstream of the separation vessel comprises expanding the gaseous refrigerant side stream in a turbo expander.

7. The method of claim 4, further comprising forming the compressed gaseous refrigerant stream from the group consisting essentially of methane, ethane, propane, and nitrogen.

8. A method of natural gas liquefaction, the method comprising:

compressing a gaseous refrigerant stream in a refrigerant loop received from a first channel of a multi-pass heat exchanger;

cooling the compressed gaseous refrigerant stream in a second channel of the multi-pass heat exchanger to form an at least partially gaseous refrigerant stream;

directing the at least partially gaseous refrigerant stream through a separation vessel downstream of the second channel of the multi-pass heat exchanger to separate a gaseous phase of the at least partially gaseous refrigerant stream from a liquid phase of the at least partially gaseous refrigerant stream;

expanding the gaseous phase of the at least partially gaseous refrigerant stream in an expansion device downstream of the separation vessel and upstream of the first channel of a multi-pass heat exchanger to form at least one expanded, at least partially gaseous refrigerant stream;

directing at least a gaseous phase of the expanded, at least partially gaseous refrigerant stream into the first channel of the multi-pass heat exchanger prior to modifying a temperature of the gaseous phase to extract heat from a gaseous natural gas process stream in a path separate from the refrigerant loop passing through a third channel of the multi-pass heat exchanger and form a cooled gaseous natural gas process stream and the gaseous refrigerant stream;

expanding the cooled gaseous natural gas process stream to form a multi-phase natural gas process stream exhibiting a liquid phase and a gaseous phase; and

directing a portion of the liquid phase of the multi-phase natural gas process stream into a fourth channel of the multi-pass heat exchanger to extract additional heat from the gaseous natural gas process stream and form a gaseous natural gas side stream.

9. The method of claim 8, wherein the gaseous refrigerant stream, the at least partially gaseous refrigerant stream, and the gaseous phase of the at least partially gaseous refrigerant stream are of a different composition than the gaseous natural gas process stream and the liquid natural gas processing stream.

10. The method of claim 8, further comprising combining the gaseous phase of the at least partially gaseous refrigerant stream and the liquid phase of the at least partially gaseous refrigerant stream in a mixer upstream of the first channel of the multi-pass heat exchanger to reform the at least partially gaseous refrigerant stream.

11. The method of claim 8, wherein directing a portion of the liquid phase of the multi-phase natural gas process stream into a fourth channel of the multi-pass heat exchanger comprises:

splitting the liquid phase of the of the multi-phase natural gas process stream into a primary liquid natural gas stream and a liquid natural gas side stream; and

directing the liquid natural gas side stream into the fourth channel of the multi-pass heat exchanger to extract heat from at least the gaseous natural gas process stream and form a gaseous natural gas side stream.

12. The method of claim 11, wherein splitting the liquid phase of the multi-phase natural gas process stream into a primary liquid natural gas stream and a liquid natural gas side stream comprises selecting a mass ratio of the primary liquid natural gas stream and the liquid natural gas side stream to be within a range of from about 3:

1 to about 9;

1.

13. The method of claim 12, further comprising:

directing the primary liquid natural gas stream into a storage vessel;

mixing the gaseous phase of the multi-phase natural gas process stream with a gaseous vent stream from the storage vessel to form a combined vent stream; and

directing the combined vent stream into a fifth channel of the multi-pass heat exchanger to extract further heat from the gaseous natural gas process stream and form a heated combined vent stream.

14. The method of claim 13, further comprising:

mixing the gaseous natural gas side stream with the heated combined vent stream to form a gaseous natural gas return stream;

compressing the gaseous natural gas return stream;

cooling the compressed gaseous natural gas return stream; and

combining the cooled, compressed gaseous natural gas return stream with a natural gas feed stream to form the gaseous natural gas process stream.

15. The method of claim 14, further comprising selecting a mass ratio of the refrigerant loop and the natural gas feed stream to be about 7.75:

1.

16. The method of claim 14, further comprising directing a portion of the gaseous natural gas process stream into the compressed gaseous refrigerant stream before directing the compressed gaseous refrigerant stream into the second channel of the multi-pass heat exchanger.

17. The method of claim 14, further comprising directing a portion of the gaseous natural gas process stream into the gaseous refrigerant stream before compressing the gaseous refrigerant stream.