LNG with ethane enrichment and reinjection gas as refrigerant

• US 6,125,653 A
• Filed: 04/26/1999
• Issued: 10/03/2000
• Est. Priority Date: 04/26/1999
• Status: Active Grant

• Current Assignee: Texaco Development Corporation (Chevron Corp.), Texaco Incorporated (Chevron Corp.)
• Original Assignee: Texaco Incorporated (Chevron Corp.)
• Inventors: Shu, Steven W., Christiano, Francis A. II
• Primary Examiner(s): CAPOSSELA, RONALD C
• Application Number:
  US09/299,259
• Time in Patent Office: 526 Days
• Field of Search: 62/622, 62/631
• US Class Current: 62/622
• CPC Class Codes: F25J 1/0022 Hydrocarbons, e.g. natural gas
• CPC Class Codes: F25J 1/0035 by gas expansion with extraction of work
• 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 1/0202 in a quasi-closed internal refrigeration loop F25J1/0208, F25J1/0219, F25J1/0224 take precedence
• 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 1/0231 for the working-up of the hydrocarbon feed, e.g. reinjection of heavier hydrocarbons into the liquefied gas
• CPC Class Codes: F25J 1/0238 Purification or treatment step is integrated within one refrigeration cycle only, i.e. the same or single refrigeration cycle provides feed gas cooling (if present) and overhead gas cooling
• CPC Class Codes: F25J 1/0271 Inter-connecting multiple cold equipments within or downstream of the cold box
• CPC Class Codes: F25J 1/0281 characterised by the type of prime driver, e.g. hot gas expander
• 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 2215/62 Ethane or ethylene
• CPC Class Codes: F25J 2215/64 Propane or propylene
• CPC Class Codes: F25J 2215/66 Butane or mixed butanes
• CPC Class Codes: F25J 2220/62 Separating low boiling components, e.g. He, H2, N2, Air
• CPC Class Codes: F25J 2230/20 Integrated compressor and process expander; Gear box arrangement; Multiple compressors on a common shaft
• CPC Class Codes: F25J 2230/60 the fluid being hydrocarbons or a mixture of 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 2240/30 : Dynamic liquid or hydraulic expansion with extraction of work, e.g. single phase or two-phase turbine
• 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 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 3/0247 : separation of CnHm with 4 carbon atoms or more

Abstract

The present invention comprises a process for producing liquefied natural gas from the methane that is produced during natural gas liquids extraction. The process includes distilling the feed to extract methane, then cooling and expanding the methane to produce liquefied natural gas and cold methane vapor. The cold methane vapor is employed as a coolant to precool the feed and to cool the methane before expansion, and is then recompressed for reinjection into the well formation. The bottoms from the methane distillation may be further distilled to extract ethane, which may be cooled with the cold methane vapor and combined with the liquefied natural gas product. A portion of the recompressed methane may be diverted from the compressor train, cooled and expanded to produce additional liquefied natural gas and cold methane vapor.

Claims

1. A process for extracting natural gas liquids from a mixture of hydrocarbons produced from a reservoir, comprising:

successively distilling the mixture to extract a methane overhead fraction from the mixture;

cooling and expanding the methane overhead fraction to produce liquefied natural gas and cold methane vapor;

recompressing at least a portion of the cold methane vapor; and

reinjecting at least part of the recompressed portion into the reservoir.

2. The process of claim 1, further comprising:

further distilling the mixture to extract an ethane overhead fraction;

cooling the ethane overhead fraction to give a cooled ethane overhead fraction; and

combining the cooled ethane overhead fraction with the liquefied natural gas.

3. The process of claim 2 wherein cooling the ethane overhead fraction comprises heat exchange between the ethane overhead fraction and the cold methane vapor.

4. The process of claim 1, further comprising cooling and expanding a portion of the recompressed portion of cold methane vapor to produce additional liquefied natural gas and additional cold methane vapor.

5. The process of claim 4, further comprising:

further distilling the mixture to extract ethane;

cooling the ethane; and

combining the cooled ethane with the liquefied natural gas.

6. The process of claim 1, wherein cooling the methane overhead fraction comprises heat exchange between the methane overhead fraction and the cold methane vapor.

7. The process of claim 6, further comprising:

further distilling the mixture to extract ethane;

cooling the ethane; and

combining the ethane with the liquefied natural gas.

8. A process for producing liquefied natural gas from methane gas, wherein the process is carried out in the vicinity of a hydrocarbon producing reservoir having an associated natural gas liquids extraction apparatus comprising a demethanizer, the process comprising:

supplying the methane gas for the process from an outlet of the demethanizer;

cooling and expanding the methane gas; and

separating liquefied natural gas from cold methane vapor.

9. The process of claim 8, further comprising cooling the methane gas from the demethanizer outlet by exchanging heat between the cold methane vapor and the methane gas.

10. The process of claim 8 wherein the natural gas liquids extraction apparatus further comprises a deethanizer, the process further comprising mixing ethane produced by the deethanizer with the liquefied natural gas.

11. An apparatus for producing liquefied natural gas from methane gas, comprising:

means for cooling the methane gas;

means for expanding the gas;

means for separating liquefied natural gas from cold methane vapor; and

a conduit to a methane gas inlet of the apparatus from a methane outlet of a demethanizer, the demethanizer being a component of a natural gas liquids extraction apparatus.

12. The apparatus of claim 11, wherein the natural gas liquids extraction apparatus further comprises a deethanizer, and the apparatus further comprises a connection between an ethane outlet of the deethanizer and a liquefied natural gas outlet of the separating means.

13. An apparatus for simultaneously producing liquefied natural gas and extracting natural gas liquids from a mixture of hydrocarbons, the apparatus comprising:

a demethanizer for distilling the mixture to produce a methane overhead fraction and a demethanizer bottoms fraction;

a turbo-expander for expanding and cooling the methane;

a separator whereby the methane is separated into liquefied natural gas and cold methane vapor;

a compressor for recompressing the cold methane vapor; and

a conduit connected between the compressor and a producing hydrocarbon reservoir such that at least a portion of the compressed methane vapor is injected into the producing hydrocarbon reservoir.

14. The apparatus of claim 13, further comprising a heat exchanger connected between the demethanizer and the turbo-expander whereby the methane overhead fraction is cooled by the cold methane vapor before the cold methane vapor is recompressed.

15. The apparatus of claim 13, further comprising a second turbo-expander whereby a portion of the portion of cold methane vapor recompressed by the compressor is expanded and cooled to produce additional liquefied natural gas.

16. The apparatus of claim 13, further comprising:

a deethanizer for removing ethane from the demethanizer bottoms fraction to produce ethane and a deethanizer bottoms fraction; and

a conduit whereby the ethane is mixed with the liquefied natural gas produced in the separator.

17. The apparatus of claim 16 further comprising a heat exchanger connected between the deethanizer and the conduit, whereby the ethane is cooled by the cold methane vapor before mixing with the liquefied natural gas.

18. The apparatus of claim 16, further comprising:

a depropanizer for further distilling the deethanizer bottoms fraction to produce propane and a depropanizer bottoms fraction; and

a debutanizer for further distilling the depropanizer bottoms fraction to produce butane and condensate.

19. The apparatus of claim 18 further comprising a heat exchanger connected between the deethanizer and the conduit, whereby the ethane is cooled by the cold methane vapor before mixing with the liquefied natural gas.

20. A process for producing liquefied natural gas from a mixture containing methane, ethane, and heavier hydrocarbons, comprising:

separating the hydrocarbon mixture into a methane-rich fraction and a methane-lean fraction;

cooling and expanding the methane-rich fraction;

separating the expanded methane-rich fraction into methane-rich liquid and methane-rich vapor, at least a portion of the methane-rich vapor accomplishing the cooling of the methane-rich fraction by heat exchange therewith;

separating at least a portion of the ethane from the methane-lean fraction;

cooling the ethane by heat exchange with at least a portion of the methane-rich vapor;

combining the methane-rich liquid with the cooled ethane to form a product mixture;

expanding the product mixture;

separating the product mixture into a liquid product and a gas product; and

recompressing the methane-rich vapor and reinjecting at least a portion of the recompressed vapor into a producing hydrocarbon reservoir.

21. The process of claim 20 wherein the expansion steps are performed in turbines, thereby generating energy for carrying out the cooling steps.

22. The process of claim 20, wherein the improvement further comprises cooling and expanding a portion of the recompressed vapor to produce additional product mixture and methane-rich vapor.

23. A process for producing ethane-enriched liquefied natural gas from a mixture of hydrocarbons, comprising:

distilling the mixture successively to produce a condensate product and a plurality of overhead products, one of the overhead products comprising methane and another comprising ethane;

liquefying at least a portion of the ethane overhead product and a first portion of the methane overhead product to form a liquefied natural gas product;

cooling the hydrocarbon mixture, the methane overhead product, and the ethane overhead product by heat exchange with a second portion of the methane overhead product; and

recompressing the second portion and injecting at least part of the second portion into a producing hydrocarbon reservoir.

24. The process of claim 23, wherein the first portion of the methane overhead product comprises a liquid portion and the second portion comprises a vapor portion.

25. The process of claim 23 further comprising cooling and expanding at least part of the recompressed second portion to produce additional liquefied natural gas product.

26. A process for separating a mixture of hydrocarbons comprising:

(a) cooling the mixture by heat exchange with a cold methane stream;

(b) distilling the cooled mixture in a demethanizer column to produce methane-rich and methane-lean fractions;

(c) distilling the methane-lean fraction in a deethanizer column to produce ethane-rich and ethane-lean fractions;

(d) cooling the methane-rich and ethane-rich fractions by heat exchange with the cold methane stream;

(e) expanding the cooled methane-rich fraction;

(f) separating the expanded methane-rich fraction to produce a first methane-rich vapor and a first methane-rich liquid;

(g) mixing the first methane-rich vapor with a second methane-rich vapor to form the cold methane stream;

(h) compressing the cold methane stream to form a compressed methane stream;

(i) injecting a portion of the compressed methane stream into a producing hydrocarbon reservoir;

(j) cooling and expanding the remaining portion of the compressed methane stream to form an incremental methane stream;

(k) separating the incremental methane stream to produce the second methane-rich vapor and a second methane-rich liquid;

(l) mixing the first and second methane-rich liquids with the cooled ethane-rich fraction to produce a product mixture;

(m) expanding the product mixture;

(n) performing a vapor-liquid separation of the expanded product mixture to produce fuel gas and liquefied natural gas.

27. The process of claim 26, further comprising separating the ethane-lean fraction into propane, butane and condensate by passing the ethane-lean fraction successively through depropanizer and debutanizer distillation columns.

28. The process of claim 26 wherein the expansion steps are performed in turbines, thereby generating energy for carrying out the cooling steps.