Superconducting System For Enhanced Natural Gas Production

• US 20120289407A1
• Filed: 01/06/2011
• Published: 11/15/2012
• Est. Priority Date: 01/27/2010
• Status: Active Grant

• Current Assignee: Eric D. Nelson, Peter C. Rasmussen, Stanley O. Uptigrove
• Original Assignee: Eric D. Nelson, Peter C. Rasmussen, Stanley O. Uptigrove
• Inventors: Nelson, Eric D, Rasmussen, Peter C, Uptigrove, Stanley o
• Granted Patent: US 9,593,881 B2
• Time in Patent Office: Days
• US Class Current: 505/163
• 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 1/0057 after expansion of the liquid refrigerant stream with extraction of work
• CPC Class Codes: F25J 1/0065 Helium
• CPC Class Codes: F25J 1/0072 Nitrogen
• CPC Class Codes: F25J 1/0082 Methane
• 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 1/0219 in combination with an internal quasi-closed refrigeration loop, e.g. using a deep flash recycle loop
• CPC Class Codes: F25J 1/023 for the combustion as fuels, i.e. integration with the fuel gas system
• CPC Class Codes: F25J 1/0236 providing refrigeration for different processes treating not the same feed stream
• CPC Class Codes: F25J 1/0247 start-up of the process
• CPC Class Codes: F25J 1/0249 Controlling refrigerant inventory, i.e. composition or quantity charging or discharging refrigerants in cooling systems F25B45/00
• 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 1/0265 comprising cores associated exclusively with the cooling of a refrigerant stream, e.g. for auto-refrigeration or economizer
• CPC Class Codes: F25J 1/0278 Unit being stationary, e.g. on floating barge or fixed platform
• CPC Class Codes: F25J 1/0279 Compression of refrigerant or internal recycle fluid, e.g. kind of compressor, accumulator, suction drum etc.
• CPC Class Codes: F25J 1/0284 : Electrical motor as the prime mechanical driver
• CPC Class Codes: F25J 1/0292 : Refrigerant compression by cold or cryogenic suction of the refrigerant gas
• CPC Class Codes: F25J 2210/06 : Splitting of the feed stream, e.g. for treating or cooling in different ways
• CPC Class Codes: F25J 2220/62 : Separating low boiling components, e.g. He, H2, N2, Air
• CPC Class Codes: F25J 2230/22 : Compressor driver arrangement, e.g. power supply by motor, gas or steam turbine
• CPC Class Codes: F25J 2230/60 : the fluid being hydrocarbons or a mixture of hydrocarbons
• CPC Class Codes: F25J 2245/90 : the recycled stream being boil-off gas from storage

Abstract

Provided is a natural gas processing facility for the liquefaction or regasification of natural gas. The facility includes a primary processing unit, e.g., refrigeration unit, for warming natural gas or chilling natural gas to at least a temperature of liquefaction. The facility also has superconducting electrical components integrated into the facility. The superconducting electrical components incorporate superconducting material so as to improve electrical efficiency of the facility by at least one percent over what would be experienced through the use of conventional electrical components. The superconducting electrical components may be one or more motors, one or more generators, one or more transfonners, switch gears, one or more electrical transmission conductors, variable speed drives, or combinations thereof.

Claims

1. A natural gas processing facility, comprising:

an electrical power source;

a primary processing unit for warming liquefied natural gas or chilling natural gas to a temperature of liquefaction;

a first refrigerant inlet line for delivering a heat exchange medium to the primary processing unit;

a natural gas inlet line for delivering natural gas to the primary processing unit;

a natural gas outlet line;

at least one superconducting electrical component which incorporates a superconducting material so as to improve electrical efficiency of the component by at least one percent over what would be experienced through the use of non-superconducting electrical components;

an incoming refrigerant line for delivering a refrigerant to the at least one superconducting electrical component for maintaining the at least one superconducting electrical component below a critical temperature; and

an outgoing refrigerant line for releasing the refrigerant from the at least one superconducting electrical component.

2. The natural gas processing facility of claim 1, wherein the facility is a natural gas liquefaction facility, the primary processing unit is a primary refrigeration unit, the heat exchange medium is a first refrigerant, and the natural gas outlet line is for releasing a substantially liquefied natural gas from the primary refrigeration unit.

3. The natural gas processing facility of claim 1, wherein the electrical power source comprises a power grid, at least one gas turbine generator, steam turbine generator, diesel generator, or combinations thereof.

4. The natural gas processing facility of claim 1, wherein the natural gas from the natural gas inlet line is pre-cooled before entry into the primary processing unit.

5. The natural gas processing facility of claim 2, wherein the primary refrigeration unit is a final refrigeration unit.

6. The natural gas processing facility of claim 1, wherein the at least one superconducting electrical component comprises one or more motors, one or more generators, one or more transformers, one or more switchgears, one or more variable speed drives, one or more electrical transmission conductors, or combinations thereof.

7. The natural gas processing facility of claim 1, further comprising an offshore unit for supporting the facility for the liquefaction or gasification of natural gas, the offshore unit comprising, a floating vessel, a ship-shaped vessel, or a mechanical structure founded on a sea floor.

8. The natural gas processing facility of claim 1, wherein the superconducting electrical components (i) weigh at least about one-third less than the weight of equivalent non-superconducting components;

(ii) have a footprint that is at least about one-third smaller than the footprint of equivalent non-superconducting components, or (iii) both.

9. The natural gas processing facility of claim 6, wherein:

the at least one superconducting electrical component comprises a motor for turning a shaft; and

the shaft turns a mechanical component of a compressor or pump for compressing or pumping a refrigerant stream or other fluid streams in the facility.

10. The natural gas processing facility of claim 2, wherein:

the facility comprises a plurality of compressors and pumps for compressing or pumping a refrigerant stream, or other fluid streams in the facility;

the at least one superconducting electrical component comprises a plurality of motors for turning respective shafts; and

the respective shafts turn corresponding mechanical components of compressors or pumps for compressing or pumping refrigerant or other fluid streams in the facility.

11. The natural gas processing facility of claim 2, wherein the refrigerant for maintaining the at least one superconducting electrical component below a critical temperature comprises liquefied natural gas, methane, ethane, ethylene, propane, a butane, a pentane, nitrogen, or a mixture of these components.

12. The natural gas processing facility of claim 11, further comprising a refrigerant slip line, the refrigerant slip line delivering a portion of the first refrigerant to the incoming refrigerant line used for delivering the second refrigerant to the at least one superconducting electrical component;

and wherein the first refrigerant and the second refrigerant are the same refrigerant.

13. The natural gas processing facility of claim 12, wherein:

the facility further comprises a warmed refrigerant outlet line for releasing warmed refrigerant from the primary refrigeration unit, and a compressor for re-compressing the warmed refrigerant in the warmed refrigerant outlet line before circulation back into the primary refrigeration unit as part of the first refrigerant; and

the warmed refrigerant from the warmed refrigerant outlet line is merged with the second refrigerant in the outgoing refrigerant line that is used for releasing the second refrigerant from the at least one superconducting electrical component so that the warmed refrigerant and the second refrigerant are together passed through the compressor.

14. The natural gas processing facility of claim 2, further comprising:

an ancillary refrigeration unit;

an incoming refrigerant slip line, the incoming refrigerant slip line taking a portion of the first refrigerant from the first refrigerant inlet line and delivering the portion of the first refrigerant to the ancillary refrigeration unit as a third refrigerant; and

an outgoing refrigerant slip line for delivering a portion of the third refrigerant to the incoming refrigerant line used for delivering the second refrigerant to the at least one superconducting electrical component.

15. The natural gas processing facility of claim 14, wherein the third refrigerant and the second refrigerant are the same refrigerant.

16. The natural gas processing facility of claim 14, wherein a duty of the ancillary refrigeration unit is controlled independently from the primary refrigeration unit.

17. The natural gas processing facility of claim 14, wherein:

the primary refrigeration unit comprises a primary warmed refrigerant outlet line for releasing warmed refrigerant from the primary refrigeration unit;

the ancillary refrigeration unit comprises an ancillary warmed refrigerant outlet line for releasing warmed refrigerant from the ancillary refrigeration unit; and

a first compressor for re-compressing the warmed refrigerant in the primary warmed refrigerant outlet line before circulation back into the primary refrigeration unit.

18. The natural gas processing facility of claim 17, wherein:

the warmed refrigerant in the ancillary warmed refrigerant outlet line is merged with the warmed refrigerant in the primary warmed refrigerant outlet line before the primary warmed refrigerant in the warmed refrigerant outlet line is re-compressed in the first compressor; and

the warmed refrigerant in the ancillary warmed refrigerant outlet line and the warmed refrigerant in the primary warmed refrigerant outlet line are released from the first compressor as the first refrigerant.

19. The natural gas processing facility of claim 17, wherein:

the second refrigerant in the outgoing refrigerant line that is used for releasing the second refrigerant from the at least one superconducting electrical component is directed into the ancillary refrigeration unit.

20. The natural gas processing facility of claim 17, wherein:

the warmed refrigerant in the ancillary warmed refrigerant outlet line is passed through a second compressor, and then merged with the warmed refrigerant in the primary warmed refrigerant outlet line before the warmed refrigerant in the primary warmed refrigerant outlet line has passed through the first compressor, thereby providing independent temperature control between the ancillary and primary refrigeration units.

21. The natural gas processing facility of claim 2, wherein:

the facility further comprises a second outlet line for releasing an independent refrigerant from the primary refrigeration unit as the second refrigerant to the at least one superconducting electrical component; and

the independent refrigerant has a composition that is different from the first refrigerant.

22. The natural gas processing facility of claim 21, wherein the second refrigerant has a cooling temperature in the incoming refrigerant line that is controlled independent of the first refrigerant in the first refrigerant inlet line to ensure operation of the superconducting electrical equipment below the critical temperature.

23. The natural gas processing facility of claim 21, wherein:

the facility further comprises an ancillary refrigeration unit;

the ancillary refrigeration unit generates the second refrigerant independent of the primary refrigeration unit; and

the ancillary refrigeration unit receives at least a portion of the second refrigerant in the outgoing refrigerant line that is used for releasing the second refrigerant from the at least one superconducting electrical component as a working fluid.

24. The natural gas processing facility of claim 23, wherein:

a portion of the primary refrigerant is directed to the ancillary refrigeration unit;

a primary warmed refrigerant outlet line releases warmed refrigerant from the primary refrigeration unit;

a primary warmed refrigerant outlet line releases warmed refrigerant from the ancillary refrigeration unit;

the outlet lines for the primary warmed refrigerant from the primary and ancillary refrigeration units are merged into a combined warm refrigerant outlet line;

a first compressor is provided for re-compressing the warmed refrigerant in the combined warmed refrigerant outlet line, the warmed refrigerant in the combined warmed refrigerant outlet line being partially cooled and then circulated back into the primary refrigeration unit as the first refrigerant and the ancillary refrigeration unit; and

a second compressor is provided for re-compressing the second refrigerant in the outgoing refrigerant line, the second refrigerant being partially cooled and then circulated back into the primary refrigeration unit.

25. The natural gas processing facility of claim 21, wherein the facility further comprises:

a primary warmed refrigerant outlet line for releasing warmed refrigerant from the primary refrigeration unit;

a first compressor for re-compressing the warmed refrigerant in the primary warmed refrigerant outlet line, the warmed refrigerant in the primary warmed refrigerant outlet line being partially cooled and then circulated back into the primary refrigeration unit as the first refrigerant; and

a second compressor for re-compressing the second refrigerant in the outgoing refrigerant line, the second refrigerant being partially cooled and then circulated back into the primary refrigeration unit.

26. The natural gas processing facility of claim 20, wherein:

the second refrigerant for maintaining the at least one superconducting electrical component below a critical temperature comprises a portion of the liquefied natural gas from the natural gas outlet line;

the portion of the liquefied natural gas is taken from the natural gas outlet line as a slip stream; and

the slip stream is in fluid communication with the incoming refrigerant line for delivering the second refrigerant to the at least one superconducting electrical component.

27. The natural gas processing facility of claim 26, wherein the facility further comprises:

a primary warmed refrigerant outlet line for releasing warmed refrigerant from the primary refrigeration unit;

a first compressor for re-compressing the warmed refrigerant in the primary warmed refrigerant outlet line, the warmed refrigerant being partially cooled and then circulated back into the primary refrigeration unit as the first refrigerant; and

a second compressor for re-compressing the second refrigerant in the outgoing refrigerant line, the second refrigerant being either (i) circulated back into the primary refrigeration unit for re-chilling, (ii) used as fuel gas for the facility, or (iii) both (i) and (ii).

28. The natural gas processing facility of claim 27, wherein:

the liquefied natural gas in the natural gas outlet line comprises heavier hydrocarbons;

the heavier hydrocarbons are removed from cooling lines delivering the second refrigerant to the at least one superconducting electrical component; and

the removed heavier hydrocarbons are reintroduced into the natural gas inlet line.

29. The natural gas processing facility of claim 27, wherein the second refrigerant in the outgoing refrigerant line is circulated back to the primary refrigeration unit.

30. The natural gas processing facility of claim 27, wherein the facility further comprises:

an end flash system that (i) receives the liquefied natural gas from the natural gas outlet line, (ii) temporarily stores the liquefied natural gas, (iii) delivers a substantial portion of the liquefied natural gas to a trans-oceanic vessel or more permanent on-shore storage, and (iv) releases end flash gas through an end-flash line; and

wherein the second refrigerant is directed to the end-flash system after cooling the at least one superconducting electrical component.

31. The natural gas processing facility of claim 30, wherein the end flash gas is circulated back into the primary refrigeration unit.

32. The natural gas processing facility of claim 20, wherein the second refrigerant in the outgoing refrigerant line is merged with the end flash gas.

33. The natural gas processing facility of claim 20, wherein:

liquefied natural gas in the natural gas outlet line is sub-cooled in the primary refrigeration unit below a critical temperature of the at least one superconducting electrical component;

at least a portion of the sub-cooled liquefied natural gas is used as the second refrigerant;

the second refrigerant in the outgoing refrigerant line is introduced into an end flash system that (i) receives the liquefied natural gas from the outgoing refrigerant line, (ii) temporarily stores the liquefied natural gas, (iii) delivers a substantial portion of the liquefied natural gas to a trans-oceanic vessel or more permanent on-shore storage, and (iv) releases end flash gas through an end-flash line.

34. The natural gas processing facility of claim 1, further comprising:

a storage device for holding a source of refrigerant;

an expansion device for cooling the source of refrigerant and releasing the source of refrigerant to the superconducting electrical components during start-up of the facility.

35. The natural gas processing facility of claim 2, further comprising:

an exit line for releasing gas from the second refrigerant in the outgoing refrigerant line and (i) delivering the gas as fuel for the facility, (ii) delivering the gas back to the primary refrigeration unit for reliquefaction, or (iii) venting the gas.

36. The natural gas processing facility of claim 27, wherein boil-off natural gas is recovered from LNG storage tanks, from loading lines, from vapors displaced during the loading of an LNG ship, or combinations thereof, and merged with the second refrigerant outlet line before feeding the second compressor.

37. The natural gas processing facility of claim 2, wherein:

the liquefied natural gas from the natural gas outlet line produces LNG end flash gas; and

the second refrigerant is cooled by chilling in heat exchange with (i) LNG end-flash gas, (ii) gas produced from boiling of an LNG storage tank, (iii) gas produced from boil-off natural gas in loading lines, (iv) gas displaced during loading of an LNG ship, or (v) combinations thereof.

38. The natural gas processing facility of claim 2, wherein improving electrical efficiency of the superconducting service by at least one percent over what would be experienced through the use of conventional electrical components comprises increasing the efficiency of liquefaction of natural gas in terms of (i) LNG per unit power, (ii) LNG per unit fuel demand, or (iii) LNG per unit emissions.