Methods and configuration of an NGL recovery process for low pressure rich feed gas

• US 10,077,938 B2
• Filed: 02/09/2016
• Issued: 09/18/2018
• Est. Priority Date: 02/09/2015
• Status: Active Grant

• Current Assignee: Fluor Technologies Corporation (Fluor Corporation)
• Original Assignee: Fluor Technologies Corporation (Fluor Corporation)
• Inventors: Mak, John
• Primary Examiner(s): Raymond, Keith
• Application Number:
  US15/019,570
• Publication Number:
  US 20160231052A1
• Time in Patent Office: 952 Days
• CPC Class Codes: C10L 3/12 Liquefied petroleum gas liquefying by pressure and cold treatment F25J
• CPC Class Codes: F25J 2200/02 in a single pressure main column system
• 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 2200/76 Refluxing the column with condensed overhead gas being cycled in a quasi-closed loop refrigeration cycle
• 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 2210/06 Splitting of the feed stream, e.g. for treating or cooling in different ways
• CPC Class Codes: F25J 2215/02 Mixing or blending of fluids to yield a certain product
• CPC Class Codes: F25J 2215/62 Ethane or ethylene
• 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 2245/02 Recycle of a stream in general, e.g. a by-pass stream
• CPC Class Codes: F25J 2270/12 External refrigeration with liquid vaporising loop
• CPC Class Codes: F25J 2270/60 Closed external refrigeration cycle with single component refrigerant [SCR], e.g. C1-, C2- or C3-hydrocarbons
• CPC Class Codes: F25J 2280/02 Control in general, load changes, different modes ("runs"), measurements
• 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

Abstract

Separating propane and heavier hydrocarbons from a feed stream by cooling the feed stream, introducing the chilled feed stream into a feed stream separation unit, pumping the separator bottom stream, introducing the pressurized separator bottom stream into a stripper column, reducing the pressure of the separator overhead stream, introducing the letdown separator overhead stream into an absorber column, collecting a stripper overhead stream from the stripper column, chilling the stripper overhead stream, reducing the pressure of the chilled stripper overhead stream, introducing the letdown stripper overhead stream into the absorber column, collecting an absorber bottom stream, pumping the absorber bottom stream, heating the absorber bottom stream, introducing the heated absorber bottom stream into the stripper column, and collecting the stripper bottom stream from the stripper column. The stripper column bottom stream includes the propane and heavier hydrocarbons and less than about 2.0% of ethane by volume.

Claims

1. A method for operating a natural gas liquids (NGL) recovery system, the method comprising:

separating a feed stream comprising methane, ethane, and propane into a propane and heavier hydrocarbon stream and an ethane-containing residue gas stream, wherein separating the feed stream comprises;

cooling the feed stream to yield a chilled feed stream;

introducing the chilled feed stream into a feed stream separation unit to yield a feed stream separator bottom stream and a feed stream separator overhead stream;

pumping the feed stream separator bottom stream to yield a pressurized feed stream separator bottom stream;

introducing the pressurized feed stream separator bottom stream into a stripper column;

reducing the pressure of the feed stream separator overhead stream using a first JT valve to yield a letdown feed stream separator overhead stream;

introducing the letdown feed stream separator overhead stream into an absorber column;

collecting a stripper column overhead stream from the stripper column;

chilling the stripper column overhead stream to yield a first chilled stripper column overhead stream utilizing refrigerant content from an absorber bottom stream;

chilling the first chilled stripper column overhead stream utilizing propane refrigeration to yield a second chilled stripper column overhead stream;

chilling the second chilled stripper column overhead utilizing refrigerant content from an absorber overhead stream to yield a third chilled stripper column overhead stream;

reducing the pressure of the third chilled stripper column overhead stream using a second JT valve to yield a letdown stripper column overhead stream;

introducing the letdown stripper column overhead stream as a lean reflux to a top of the absorber column, wherein the lean reflux is a two phase stream;

collecting the absorber bottom stream from the absorber column;

pumping the absorber bottom stream to yield a pressurized absorber bottom stream;

heating the pressurized absorber bottom stream to yield a heated absorber bottom stream;

introducing the heated absorber bottom stream to a top of the stripper column;

supplying heat to the stripper column; and

collecting a stripper column bottom stream from the stripper column, wherein the stripper column bottom stream forms the propane and heavier hydrocarbon stream and wherein the propane and heavier hydrocarbon stream comprises propane and heavier hydrocarbons and less than about 2.0% of ethane by volume.

2. The method of claim 1, wherein cooling the feed stream comprises introducing the feed stream into a first heat exchanger and a second heat exchanger.

3. The method of claim 2, wherein heating the pressurized absorber bottom stream comprises introducing the pressurized absorber bottom stream into a third heat exchanger.

4. The method of claim 3, wherein chilling the stripper column overhead stream comprises heat exchanging the stripper column overhead stream and the absorber bottom stream in the third heat exchanger, wherein chilling the first chilled stripper column overhead stream comprises heat exchanging the first chilled stripper column overhead stream and propane in a fourth heat exchanger, and wherein chilling the second chilled stripper column overhead stream comprises heat exchanging the second chilled stripper column overhead stream and the absorber overhead stream in the first heat exchanger.

5. The method of claim 2, wherein separating the feed stream further comprises:

collecting the absorber overhead stream from the absorber column, wherein the absorber overhead stream forms the ethane-containing residue gas stream.

6. The method of claim 5, further comprising:

heating the absorber overhead stream in the first heat exchanger to form a heated residue gas stream;

compressing the heated residue gas stream to yield a compressed residue gas stream; and

cooling the compressed residue gas stream to yield a cooled residue gas stream.

7. The method of claim 6, wherein cooling the compressed residue gas stream comprises introducing the compressed residue gas stream into a fifth heat exchanger.

8. The method of claim 6, further comprising:

separating ethane from the cooled residue gas stream, wherein separating ethane from the cooled residue gas stream comprises;

splitting the cooled residue gas stream into a first portion and a second portion;

cooling the first portion of the cooled residue gas stream to yield a cooled first portion residue gas stream;

reducing the pressure of the first portion of the cooled residue gas stream to yield a letdown first portion residue gas stream;

introducing the letdown first portion residue gas stream into a demethanizer column as a demethanizer reflux stream;

cooling a second portion of the cooled residue gas stream to yield a cooled second portion residue gas stream;

introducing the cooled second portion residue gas stream into a residue gas separator to yield a residue gas separator bottom stream and a residue gas separator overhead stream;

reducing the pressure of the residue gas separator bottom stream to yield a letdown residue gas separator bottom stream;

introducing the letdown residue gas separator bottom stream into a mid-section of the demethanizer column;

reducing the pressure of the residue gas separator overhead stream to yield a letdown residue gas separator overhead stream;

introducing the letdown residue gas separator overhead stream into an upper portion of the demethanizer column;

collecting a demethanizer column bottom stream, wherein the demethanizer column bottom stream comprises at least 98% ethane by volume.

9. The method of claim 8, wherein cooling the first portion of the cooled residue gas stream comprises introducing the first portion of the cooled residue gas stream into a sixth heat exchanger.

10. The method of claim 8, wherein cooling the second portion of the cooled residue gas stream comprises introducing the second portion of the cooled residue gas stream into a demethanizer reboiler heat exchanger.

11. The method of claim 8, wherein reducing the pressure of the first portion of the cooled residue gas stream comprises introducing the first portion of the cooled residue gas stream into a third JT valve.

12. The method of claim 9, further comprising:

heating a demethanizer column overhead stream in the sixth heat exchanger to form a heated demethanizer column overhead stream, wherein the demethanizer column overhead stream comprises a substantially ethane-free residue gas stream;

compressing the heated demethanizer column overhead stream to form a compressed demethanizer column overhead stream; and

cooling a portion of the compressed demethanizer column overhead stream to form a cooled residue gas return stream;

reducing a pressure of the cooled residue gas return stream using a forth JT valve to form a methane rich reflux stream; and

feeding the methane rich reflux stream to the demethanizer column.

13. The method of claim 1, wherein the propane and heavier hydrocarbon stream comprises at least about 95 vol. % of the propane present within the feed stream.

14. The method of claim 1, wherein the propane and heavier hydrocarbon stream comprises at least about 99 vol. % of the C4 and heavier hydrocarbons present within the feed stream.

15. A natural gas liquids (NGL) recovery system commprising:

a deep dewpointing subsystem (DDS) configured to separate a feed stream comprising methane, ethane, and propane into a propane and heavier hydrocarbon stream and an ethane-containing residue gas stream, the DDS comprising;

a first heat exchanger configured to receive the feed stream and to output a chilled feed stream;

a feed stream separation unit configured to receive the chilled feed stream and to output a feed stream separator bottom stream and a feed stream separator overhead stream;

a first JT Valve configured to reduce the pressure of the feed stream separator overhead stream to yield a letdown feed stream separator overhead stream;

an absorber column configured to receive the letdown feed stream separator overhead stream into the absorber column and to produce an absorber bottom stream;

a first pump configured to receive the absorber bottom stream to output a pressurized absorber bottom stream;

a stripper column configured to receive the feed stream separator bottom stream and the pressurized absorber bottom stream and to output a stripper column overhead stream and a stripper column bottom stream, wherein the stripper column overhead stream comprises methane and ethane;

a second heat exchanger configured to chill the stripper column overhead stream and to heat the compressed absorber bottom stream and to output a first chilled stripper column overhead stream and a heated absorber bottom stream;

a third heat exchanger configured to further chill the first chilled stripper column overhead stream and to output a second chilled stripper column overhead stream,

wherein the first heat exchanger is configured to further chill the second chilled stripper column overhead stream and to output a third chilled stripper column overhead stream,

a second JT valve configured to reduce the pressure of the third chilled stripper column overhead stream to yield a lean reflux stream,

wherein the lean reflux stream is fed to a top of the absorber column, and

wherein the stripper column bottom stream forms the propane and heavier hydrocarbon stream and wherein the propane and heavier hydrocarbon stream comprises propane and heavier hydrocarbons and less than about 2.0% of ethane by volume.

16. The system of claim 15, wherein the absorber column is further configured to output an absorber overhead stream, wherein the absorber overhead stream forms the ethane-containing residue gas stream.

17. The system of claim 16, wherein the first heat exchanger is configured to heat the absorber overhead stream and to output a heated residue gas stream.

18. The system of claim 17, further comprising:

an ethane-recovery subsystem (ERS) configured to separate ethane from the heated residue gas stream, wherein the ERS comprises;

a first compressor configured to receive the heated residue gas stream and to output a compressed residue gas stream;

a fourth heat exchanger configured to cool the compressed residue gas stream to yield a cooled residue gas stream;

a fifth heat exchanger configured to cool a first portion of the cooled residue gas stream and to output a cooled first portion residue gas stream;

a third JT valve configured to reduce the pressure of the cooled first portion residue gas stream and to output a letdown first portion residue gas stream;

a demethanizer column configured to receive the letdown first portion residue gas stream and a methane rich reflux stream, wherein the demethanizer column is further configured to produce a demethanizer column overhead stream and a demethanizer column bottom stream, wherein the fourth heat exchanger is further configured to heat the demethanizer column overhead stream to form a heated demethanizer column overhead stream;

a second compressor configured to receive the heated demethanizer column overhead stream and to output a compressed demethanizer column overhead stream, wherein a portion of the compressed demethanizer column overhead stream is cooled in the fifth heat exchanger to form a cooled residue gas return stream;

a fourth JT valve configured to reduce the pressure of the cooled residue gas return stream to form the methane rich reflux stream;

a demethanizer reboiler heat exchange configured to cool a second portion of the chilled residue gas stream and to output a cooled second portion residue gas stream;

a residue gas separator configured to receive the cooled second portion residue gas stream and to output a residue gas separator bottom stream and a residue gas separator overhead stream;

a fifth JT valve configured to reduce the pressure of the residue gas separator bottom stream to output a letdown residue gas separator bottom stream;

wherein the demethanizer column is further configured to receive the letdown residue gas separator bottom stream into a mid-section of the demethanizer column;

a turbo-expander configured to reduce the pressure of the residue gas separator overhead stream and to output a letdown residue gas separator overhead stream;

wherein the demethanizer column is further configured to receive the letdown residue gas separator overhead stream into an upper portion thereof; and

wherein the demethanizer column bottom stream comprises at least 98% ethane by volume.

19. The system of claim 18, wherein the demethanizer column overhead stream comprises a substantially ethane-free residue gas stream.

20. The system of claim 15, wherein the propane and heavier hydrocarbon stream comprises at least about 95 vol. % of the propane present within the feed stream.

21. The system of claim 15, wherein the propane and heavier hydrocarbon stream comprises at least about 99 vol. % of the C4 and heavier hydrocarbons present within the feed stream.