U.S. patent application number 14/645677 was filed with the patent office on 2016-09-15 for light gas separation process and system.
The applicant listed for this patent is MICHAEL J. DRAY, Henry Edward Howard. Invention is credited to MICHAEL J. DRAY, Henry Edward Howard.
Application Number | 20160265842 14/645677 |
Document ID | / |
Family ID | 55854550 |
Filed Date | 2016-09-15 |
United States Patent
Application |
20160265842 |
Kind Code |
A1 |
DRAY; MICHAEL J. ; et
al. |
September 15, 2016 |
LIGHT GAS SEPARATION PROCESS AND SYSTEM
Abstract
The present invention relates in one respect to a process for
separating light gas components, preferably helium, from a stream
containing predominantly carbon dioxide, and in another respect is
directed to a process for purifying a feed stream containing
predominantly carbon dioxide into a high grade carbon dioxide
product stream using a warm distillation process as the primary
carbon dioxide separation step.
Inventors: |
DRAY; MICHAEL J.; (Amherst,
NY) ; Howard; Henry Edward; (Grand Island,
NY) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
DRAY; MICHAEL J.
Howard; Henry Edward |
Amherst
Grand Island |
NY
NY |
US
US |
|
|
Family ID: |
55854550 |
Appl. No.: |
14/645677 |
Filed: |
March 12, 2015 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F25J 3/08 20130101; Y02C
20/40 20200801; F25J 2205/40 20130101; Y02C 10/12 20130101; B01D
2256/22 20130101; B01D 2257/30 20130101; C01B 23/0036 20130101;
F25J 2205/60 20130101; B01D 2257/80 20130101; C01B 2210/0053
20130101; F25J 3/067 20130101; F25J 3/069 20130101; F25J 2205/80
20130101; Y02C 10/04 20130101; B01D 53/261 20130101; F25J 3/0209
20130101; F25J 2220/02 20130101; Y02P 20/152 20151101; B01D 53/002
20130101; B01D 53/265 20130101; F25J 2205/82 20130101; B01D
2257/108 20130101; C01B 2210/0031 20130101; F25J 2260/80 20130101;
B01D 53/75 20130101; F25J 3/029 20130101; F25J 2280/02 20130101;
F25J 3/0266 20130101; F25J 2230/80 20130101; B01D 2257/702
20130101; Y02P 20/151 20151101; C01B 2210/0051 20130101; F25J
2215/80 20130101; F25J 2230/32 20130101; B01D 2257/11 20130101 |
International
Class: |
F25J 3/06 20060101
F25J003/06 |
Claims
1. A process for separating a light gas fraction from a feed stream
containing at least 85% CO2 at a pressure of at least 500 psia and
having a dew point temperature below about 20.degree. F. comprising
the following steps: cooling and condensing at least a portion of
the feed stream to a temperature (T.sub.1) of not less than
25.degree. F. below the dry gas dew point of the at least a portion
of the feed stream to form a first carbon dioxide enriched stream
having a purity greater than about 95% by volume carbon dioxide and
a first light gas enriched stream; recovering the first carbon
dioxide enriched stream; cooling and condensing the first light
fraction stream at a temperature of less than about minus
40.degree. F. to form a second carbon dioxide enriched stream and a
second light gas enriched stream; recovering the second carbon
dioxide enriched stream; passing the second light gas stream
through a CO2 removal unit to remove residual carbon dioxide and
form a third carbon dioxide rich stream having a purity greater
than 95% by volume carbon dioxide and a third light gas enriched
stream; and recovering the third carbon dioxide enriched
stream.
2. The process of claim 1 wherein one or more of the carbon dioxide
enriched streams are recovered as a high grade carbon dioxide
product stream.
3. The process of claim 1 wherein the second light gas enriched
stream is passed through a catalytic oxidation unit to remove
hydrogen prior to being passed to the CO2 removal unit; the third
light gas enriched stream is passed through a cryogenic
distillation unit to produce a helium rich stream and a byproduct
stream; the helium rich stream is then passed through a helium
separation unit to produce a helium product gas stream having a
purity of greater than 85% helium by volume.
4. The process of claim 3 wherein the helium product gas stream is
at purities of greater than 99.99% helium by volume.
5. The process of claim 1 wherein a warm distillation is used for
condensing at least a portion of the feed stream.
6. The process of claim 5 where the warm distillation is conducted
at temperatures of not less than about 20.degree. F.
7. The process of claim 1 wherein at least 33% by volume of the
available carbon dioxide in the feed stream is separated during the
cooling and condensing step.
8. The process of claim 1 wherein the first carbon dioxide rich
stream is partially condensed by indirect heat exchange with a
refrigerant stream.
9. The process of claim 8 wherein the refrigeration is derived from
depressurizing at least a portion of the first carbon dioxide rich
stream to a pressure lower than the feed pressure and a temperature
T.sub.2 higher than T.sub.1, and substantially vaporizing the
carbon dioxide rich stream in indirect heat exchange with a cooling
feed stream.
10. The process of claim 9 wherein a refrigerating stream obtained
at a temperature T3 which is lower than T1 is subjected to indirect
heat exchange with the feed stream for cooling the feed stream to a
temperature T1 from T2.
11. The process of claim 11 where the refrigerating stream at T3 is
a portion of the first carbon dioxide rich stream.
12. The process of claim 1 wherein the feed stream is a naturally
occurring stream obtained from a well that is dried in a bulk
dryer.
13. The process of claim 2 wherein the cooling and partially
condensing is conducted at temperatures above about 30.degree. F.
and pressures ranging from about 500 to about 900 psia.
14. The process of claim 3 wherein the byproduct stream is
compressed and returned to one or more of the carbon dioxide
enriched streams.
15. The process of claim 1 wherein the first light gas enriched
stream is compressed prior to deep cold separation.
16. The process of claim 1 wherein prepurification of the feed
stream is conducted to remove particulates or contaminants.
17. A process for recovering helium from a feed stream containing
at least about 0.5% helium and predominantly carbon dioxide and
having a dew point temperature below about 20.degree. F.
comprising: cooling and partially condensing at least a portion of
the feed stream to form a first carbon dioxide enriched stream
having greater than 95% by volume carbon dioxide and a first light
gas enriched stream; recovering the first carbon dioxide enriched
stream; cooling and condensing the first light gas enriched stream
at a temperature of less than about minus 40.degree. F. into a
second carbon dioxide enriched stream and a second light gas
enriched stream; recovering the second carbon dioxide enriched
stream; passing the second light gas enriched stream through a
catalytic oxidation unit to form a hydrogen lean stream; passing
the hydrogen lean stream through a CO2 removal unit to remove
residual carbon dioxide and form a third carbon dioxide rich stream
having greater than 95% by volume carbon dioxide and a third light
gas enriched stream; capturing the third carbon dioxide enriched
stream; passing the third light gas enriched stream through a
cryogenic distillation unit to produce a helium rich stream and a
byproduct stream; passing the helium rich stream through a helium
separation unit to form a waste light fraction stream and a helium
product gas stream at purities of greater than 95% helium by
volume; and recovering the helium product gas stream.
18. The process of claim 17 wherein the helium product gas stream
is at a purity of greater than 99.99% helium by volume.
19. The process of claim 18 wherein the cooling and partially
condensing at least a portion of the feed stream is conducted at
temperatures above about 30.degree. F. and pressures ranging from
about 500 to about 900 psia.
20. The process of claim 17 wherein the byproduct stream is
compressed and returned to one or more of the carbon dioxide
enriched streams.
Description
FIELD OF THE INVENTION
[0001] The present invention relates generally to a process and
system for separating light gas fractions from feed streams
comprising predominately carbon dioxide. In one respect, the
present process is directed to separating such light gas
components, and most preferably to recovering helium, while in
another respect the invention is directed to purifying a feed
stream containing predominantly carbon dioxide into a high grade
carbon dioxide product stream.
BACKGROUND OF THE INVENTION
[0002] Carbon dioxide (CO.sub.2) is a naturally occurring chemical
compound useful in a wide range of biological and industrial
processes. It is produced during the respiration of aerobic
organisms and during the decay of organic materials and can be
found in high concentration in natural sites underground. It is
also produced as a by-product of multiple industrial processes such
as the combustion of fossil fuels, the production of hydrogen by
reforming, ammonia synthesis, and fermentation. It has a variety of
uses in both gaseous and liquid state. For example, carbon dioxide
is used in the food and beverage industry, the welding industry,
and the oil production/recovery industry. It is also used as a
solvent, flame retardant, refrigerant and in biological and
agricultural applications.
[0003] Many of these uses require that the carbon dioxide feed
stream contain sufficient concentrations of carbon dioxide to be
considered a high grade carbon dioxide stream with some uses
requiring a high grade stream of more than 98% carbon dioxide by
volume. In some instances, the carbon dioxide streams contain
meaningful quantities of deep condensable gases; some of which are
highly valuable and therefore desirable to capture.
[0004] One example of a valuable deep condensable gas is helium.
Helium is an industrially important rare gas. For large-scale
production, it is normally extracted by fractional distillation
from natural gas, which can contain up to 9% helium, but is
generally present in amounts of 0.2 to 2%. Helium has unique
physical properties making it valuable in a wide range of
commercial applications. Typical commercial applications range from
balloons to lasers and include heat transfer and cooling
applications; shielding applications; gas tracing applications;
inert environments; and numerous other commercial applications.
However, due to its limited availability and increasing commercial
demand its cost has risen substantially.
[0005] The past thirty years, and particularly the past decade, has
seen a dramatic rise in the use of carbon dioxide for enhanced oil
recovery. From 2002 to 2012, oil production using carbon dioxide
enhancement increased from 190,000 barrels per day to over 300,000.
Rather than using anthropogenic sources, much of this growth in CO2
use has come from natural wells with high carbon dioxide content.
Concentrations of CO2 from such wells can be above 85% and even
above 95% by volume.
[0006] The need for large quantities of carbon dioxide for use in
applications such as enhanced oil recovery has prompted the
development of more carbon dioxide sources including the capture of
industrially produced carbon dioxide and the development of carbon
dioxide rich natural wells. These gases, particularly natural
deposits, often include significant amounts of light gas
impurities, such as the rare gases including helium. The recovery
and processing of these gases and particularly helium can
substantially improve the overall economics of carbon dioxide
production for enhanced oil recovery and other large applications
by providing additional revenue generating products.
[0007] Thus, recovering the light gas fractions, such as the rare
gases and particularly helium, from such carbon dioxide containing
streams has become a valuable commercial opportunity if the
recovery can be accomplished efficiently and inexpensively. The two
common processes for removing light fractions or condensable
fractions from heavier fractions include solvents, adsorption or
extraction and cryogenic fractionation as are well known. These
more traditional processes are normally not economical for this
purpose due to the high cost of equipment and/or reactants.
BRIEF SUMMARY OF THE INVENTION
[0008] The present invention is directed to removing light
components, lighter than carbon dioxide, and preferably helium from
a carbon dioxide containing streams, such as commercial grade or
naturally occurring streams containing at least 85% carbon dioxide.
It is also directed to purifying a feed stream containing
predominantly carbon dioxide to a high grade carbon dioxide product
stream. The present process employs a first cooling and
condensation step using a "warm distillation" process to reduce or
eliminate the fine pre-drying step and the associated capital costs
and operating energy requirements. The cooling and condensation
process of this invention acts as a first and primary separation
step to separate a significant portion of the light gas components
and reduce the processing gas volume prior to conducting additional
or fine separation steps. Additional separation and processing
steps can then be conducted on smaller volumes of process gas using
less capital intense equipment and lower operating costs.
[0009] According to this invention, a process is provided for
separating a light gas fraction from a feed stream containing at
least 85% CO2 at a pressure of at least 500 psia and having a dew
point temperature below about 20.degree. F. comprising the
following steps:
[0010] cooling and condensing at least a portion of the feed stream
to a temperature (T1) of not less than 25.degree. F. below the dry
gas dew point of the at least a portion of the feed stream to form
a first carbon dioxide enriched stream having a purity greater than
about 95% by volume carbon dioxide and a first light gas enriched
stream;
[0011] recovering the first carbon dioxide enriched stream;
[0012] cooling and condensing the first light fraction stream at a
temperature of less than about minus 40.degree. F. to form a second
carbon dioxide enriched stream and a second light gas enriched
stream;
[0013] recovering the second carbon dioxide enriched stream;
[0014] passing the second light gas stream through a CO2 removal
unit to remove residual carbon dioxide and form a third carbon
dioxide rich stream having a purity greater than 95% by volume
carbon dioxide and a third light gas enriched stream; and
[0015] recovering the third carbon dioxide enriched stream.
[0016] Also provided is a process for recovering helium from a feed
stream containing at least about 0.5% helium and predominantly
carbon dioxide and having a dew point temperature below about
20.degree. F. comprising
[0017] cooling and partially condensing at least a portion of the
feed stream to form a first carbon dioxide enriched stream having
greater than 95% by volume carbon dioxide and a first light gas
enriched stream;
[0018] recovering the first carbon dioxide enriched stream;
[0019] cooling and condensing the first light gas enriched stream
at a temperature of less than about minus 40.degree. F. into a
second carbon dioxide enriched stream and a second light gas
enriched stream;
[0020] recovering the second carbon dioxide enriched stream;
[0021] passing the second light gas enriched stream through a
catalytic oxidation unit to form a hydrogen lean stream;
[0022] passing the hydrogen lean stream through a CO2 removal unit
to remove residual carbon dioxide and form a third carbon dioxide
rich stream having greater than 95% by volume carbon dioxide and a
third light gas enriched stream;
[0023] capturing the third carbon dioxide enriched stream;
[0024] passing the third light gas enriched stream through a
cryogenic distillation unit to produce a helium rich stream and a
byproduct stream;
[0025] passing the helium rich stream through a helium separation
unit to form a waste light fraction stream and a helium product gas
stream at purities of greater than 95% helium by volume; and
[0026] recovering the helium product gas stream.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] While the specification concludes with claims distinctly
pointing out the subject matter that Applicants regard as their
invention, it is believed that the invention will be better
understood when taken in connection with the accompanying drawings
in which:
[0028] FIG. 1 is a schematic process flow diagram of an apparatus
for carrying out a method in accordance with the present
invention.
DETAILED DESCRIPTION OF THE INVENTION
[0029] According to this invention, light gas fractions are removed
from a feed stream comprising predominately carbon dioxide in a
multiple step process designed to be highly efficient using reduced
capital equipment requirements. The light gas components or
fraction can comprise rare gases, hydrocarbons, hydrogen,
atmospheric gases, and other trace gases which have densities less
than that of carbon dioxide. Such feed streams can be found as a
naturally occurring underground gas supply in a well or as the
production or waste stream from various industrial processes. The
present process uses a low cost first cooling and condensation step
as the primary separation process thereby removing the bulk of the
light fraction gases without the need for, or otherwise in the
absence of, cryogenic or deep cold liquefaction separation
requirements and temperatures as the primary or bulk separation
process. The temperatures employed during this primary separation
step, referred herein as a warm distillation process, are
significantly above conventional commercial cryogenic separation
temperatures.
[0030] While not intended to limit the scope of this invention, a
preferred embodiment is provided in FIG. 1 showing a process for
recovering the light gas components from a feed stream containing
predominantly carbon dioxide which are further processed to recover
helium. With reference to the embodiment shown in FIG. 1, process 1
is designed to recover one or more light gas components from carbon
dioxide feed stream 2 at elevated pressure. In this embodiment,
carbon dioxide feed stream 2, having at least 85% carbon dioxide by
volume, is taken from a carbon dioxide feed source and is typically
already at pressure, such as from a CO2 compression system
associated with a natural well. However, carbon dioxide feed stream
2 can be pressurized if from a low pressure source or depressurized
if from a super critical pressure source using conventional
systems.
[0031] The separation of the light gas fraction results in the
recovery of high grade carbon dioxide streams. As previously
discussed, high grade carbon dioxide streams have numerous
applications including the injection of such streams into
underground formations to promote enhanced oil recovery.
[0032] In accordance with this embodiment, carbon dioxide feed
stream 2 which can be a naturally occurring stream obtained from a
well or a stream from a commercial process is taken at
super-atmospheric pressure generally ranging from above about 500
psia and preferably from about 500 to about 900 psia, is dried in
bulk dryer 10 and passed into a cooling and condensation unit 20.
Although not shown here, the carbon dioxide feed stream 2 can be
taken directly into unit 20 without drying, provided that the dew
point of feed stream 2 is below about 20.degree. F., below which
water vapor will condense and leave the feed stream as liquid
water. Such a feed stream, or the stream after drying, is referred
to herein as dry carbon dioxide feed stream 12. Carbon dioxide feed
streams having a dew point above about 20.degree. F., are dried in
bulk dryer 10 which is designed to be a low cost method to
incompletely remove water vapor, but still render a sufficiently
dry feed stream. Such dryers are considerably less expensive as
compared to "fine" dryers capable of removing higher amounts of
water as are required prior to deep cold or cryogenic distillation
processes. Bulk dryer 10 can be used to remove water vapor to a dew
point specification of below about 20.degree. F., and more
preferably below -10.degree. F. and most preferably below about
-30.degree. F., but is not required if the carbon dioxide feed
stream 12 has a dew point temperature below about 20.degree. F. For
clarification, the description of the dew point here and its
calculation for determining whether bulk drying is required
includes water content.
[0033] Prepurification of carbon dioxide feed stream 2 can also
optionally be conducted (not shown) to remove certain particulates
or contaminants as needed. Such prepurification would be conducted
through the use of adsorbents or absorbents as is known. However,
in the initial phase of separation as shown in this embodiment, it
is preferred to minimize gas processing. Associated costs and
pretreatment processes are generally avoided when possible.
[0034] Dry carbon dioxide feed stream 12 contains predominantly
carbon dioxide, hydrocarbons and atmospheric gases such as rare
gases and helium. In a preferred embodiment of this invention,
helium gas is recovered from the light gas fraction and, for such
applications; carbon dioxide feed stream 2 will contain at least
about 0.5% helium and preferably 1% or more helium by volume. As
used herein, "containing predominantly carbon dioxide" means a
stream with more than 85% and, preferably more than 90% by volume
carbon dioxide. Preferably, the total hydrocarbon concentration of
carbon dioxide feed stream 2 will be below 15% and more preferably
below 10% by volume. A high grade carbon dioxide stream as used
here means a stream having at least 95% and preferably at least 98%
carbon dioxide by volume. Both such streams, will preferably have
low concentrations of contaminant gases such as oxygen, argon,
sulfur compounds and nitrogen oxides, such as less than 500 ppm,
more preferably less than 100 ppm of each.
[0035] Bulk dryer 10 is preferably a glycol dehydration system
wherein a liquid desiccant is used for the removal of water and
other trace impurities from feed stream 2. Such processes are well
known and are commonly used to remove water from process gas
streams, such as natural gas streams. Depending on the specific
process, other known drying or separation processes can be used
such as adsorption systems that contain one or more beds of
molecular sieve adsorbent or alumina; regenerative desiccant
dryers, often called "regens" or "twin tower" dryers, and
non-adsorbent based systems such as reversing heat exchangers. Dry
carbon dioxide feed stream 12, either received in such a dry state
or after bulk drying is cooled in a heat exchanger section of unit
20 (unit 20 having a heat exchanger along with a distillation
column) which partially liquefies the stream. Feed stream 12 is
cooled to a temperature T.sub.1 of not more than about 25.degree.
F. below its "dry gas dew point" (as used herein) and while some
water may remain in the stream, it is important to note that the
water is not considered here in calculating T.sub.1. Conventional
heat exchange systems can be employed for the effective recovery of
or reuse of heat energy between the dry carbon dioxide feed stream
12 and one or more product streams leaving unit 20 or other process
gasses as described below.
[0036] Dry carbon dioxide feed stream 12, still at pressure, is
sent to the "warm" distillation column in unit 20 to conduct the
first and primary phase separation. This condensation and
separation step is considered a warm process since temperatures
significantly above conventional CO2 distillation separation
temperatures are used. The amount of carbon dioxide that can be
recovered in the warm distillation is a function of the feed
pressure, condensation temperature, feed composition and operating
conditions of the distillation section of unit 20. As is
appreciated by the skilled person, the recovery may be increased by
increasing this pressure although an increase in pressure may
result in greater production costs. The optimum pressure will
therefore vary with the particular application and, for the
embodiment shown, will typically range from about 500 to about 900
psia. For this embodiment, at least 33% by volume of the available
carbon dioxide will be separated from dry feed stream 12 during the
primary separation step (cooling and condensing step). In the event
that dry feed stream 12 had a carbon dioxide content of greater
than 97% by volume, then approximately 90% of the available carbon
dioxide will be separated from feed stream 2 during this primary
phase separation stage.
[0037] As previously stated, the distillation column in unit 20 is
operated at temperatures that are significantly warmer than typical
carbon dioxide distillation processes. The distillation column in
unit 20 is operated at temperatures of not more than about
25.degree. F. below the dew point of the dry carbon dioxide feed
stream 12, such dew point being determined without considering the
water content. The distillation column in unit 20 will typically be
operated at temperatures above about 20 degrees F., and preferably
above 30 degrees F. The process for the primary carbon dioxide
phase separation step is therefore conducted in the absence of a
cryogenic or deep cold liquefaction process and in the absence of
cryogenic or deep cold separation temperatures. The warm
distillation step being above cryogenic, generally minus 70.degree.
F., or deep cold temperatures, between about minus 40.degree. to
minus 70.degree. F., provides numerous advantages, such as a lower
operating and capital costs. It is also possible to run the warm
distillation column in unit 20 in a manner which optimizes recovery
of light gases if recovery of a higher value light product is
desired to enhance process economics. In addition, due to a less
stringent water removal requirement, the upstream drying equipment
can be designed to also have lower operating and capital costs.
[0038] According to this embodiment, at least two streams exit the
warm distillation column in unit 20 with two streams being shown in
FIG. 1. First carbon dioxide rich stream 22 will contain greater
than 95% by volume, preferably greater than 97% by volume, of
carbon dioxide. First carbon dioxide rich stream 22 will be
substantially depleted of deep condensable gases such as any rare
gases (including helium) and is subjected to recompression in unit
18. Recompression unit 18 may include several stages of compression
and associated intercooling to maximize efficiency as is known.
First carbon dioxide rich stream 22 can be captured or returned to
the source compression train as desired. Refrigeration for cooling
of dry carbon dioxide stream 12 for continued processing can come
from an external refrigerant stream or another internal side stream
used as the refrigerant stream. Optionally, at least part of the
pressure of first carbon dioxide rich stream 22 can be reduced and
then substantially vaporized by warming it in indirect heat
exchange with feed stream 12 (not shown). In this embodiment, a
portion of first carbon dioxide rich stream 22 is depressurized by
between about 50 to about 200 psig, and a temperature T.sub.2
higher than T.sub.1, and is substantially vaporized in indirect
heat exchange with a cooling feed stream. A refrigerating stream,
which can be a second portion of first carbon dioxide rich stream
22, obtained at a temperature T.sub.3 which is lower than T.sub.1
is subjected to indirect heat exchange with the feed stream 12 for
cooling feed stream 12 to a temperature T.sub.1 from T.sub.2.
Splitting the refrigeration load in this way can process economics
by lowering the total recompression necessary. First carbon dioxide
rich stream 22, either with or without heat exchange, can be
repressurized in recompression unit 18 as needed.
[0039] As described, first carbon dioxide rich stream 22 can be
substantially vaporized by indirect heat exchange with at least a
partial stream from feed stream 12 (not shown) to improve the
efficiency of the process. Alternatively, a refrigeration stream
can be used to substantially condense carbon dioxide rich feed
stream 22 which can be either a second stream taken from carbon
dioxide rich stream 22 and expanded, or a separate stream used for
this purpose such as a refrigerant gas, propane or similar
hydrocarbon containing gas (also not shown).
[0040] First light gas enriched stream 24 is the second stream
shown leaving unit 20 and is typically less than about 10% of the
total feed gas volume when feed gas stream 2 is greater than 95% by
volume carbon dioxide. All processing steps after the primary phase
separation step will be conducted on a substantially smaller volume
of gas reducing process and equipment costs. In order to optimize
the process for a particular feed stream, the first light gas
enriched stream 24 can be optionally compressed prior to deep cold
separation as described below. First light gas enriched stream 24
will contain residual carbon dioxide and the light gas components.
First light gas enriched stream 24 is optionally sent to fine
drying unit 26 to remove any remaining moisture as may be required
to avoid condensation/solidification prior to deep cold separation
and will result in a first light gas enriched stream 24 converted
into stream 28 (the dry first light gas enriched stream 28 leaving
the optional fine drying unit 26 as shown) having a dew point of
less than about minus 70.degree. F. First light gas enriched stream
28 leaving optional unit 26 is sent to deep cold condensation unit
30 for further separation. Optional fine drying unit 26 is
typically an adsorbent type drying system. The use and operation of
such fine dryers is well known and they are commercially
available.
[0041] First light gas enriched stream 28 is then passed to deep
cold condensation unit 30 and phase separated into at least two
streams; second carbon dioxide rich stream 32 and second light gas
enriched stream 34. Deep cold condensation unit 30 is used for the
secondary carbon dioxide phase separation step and is typically
conducted at temperatures of between minus 40.degree. F. and minus
70.degree. F. and is preferably at about minus 60 degrees F. Second
carbon dioxide rich stream 32 will be at purity concentrations of
over 98%. Second carbon dioxide rich stream 32 is depressurized and
can be vaporized by warming it in indirect heat exchange with the
partially condensing first light gas enriched stream 28 (heat
exchange not shown). Second carbon dioxide rich stream 32 may
consist of two or more separate streams from deep cold separation
unit 30 which can be combined as one stream as desired. Second
carbon dioxide rich stream 32 can be sent for recompression in
recompression unit 18 or can be sent as shown to carbon dioxide
rich stream 22 prior to recompression and prior to being recovered
as desired.
[0042] Second light gas enriched stream 34 goes through further
processing before cryogenic light gas recovery. Second light gas
enriched stream 34 may consist of two or more separate streams from
cold separation unit 30 which can be again combined into one stream
as desired. Alternative embodiments for section 110 of the process
may be possible to optimize the process based on the particular
feed stream, and may require more or less of the identified process
units as needed. For instance, catalytic oxidation unit 40
described below could be placed after the final carbon dioxide
removal unit 50, or may be eliminated from the process as is
apparent to one skilled in the art based on the feed stream
composition and process requirements. In the embodiment as shown,
second light gas enriched stream 34, containing the light gas
components including any hydrocarbons is sent to a sulfur removal
unit 36. Sulfur removal unit 36 may be an absorbent or adsorbent
type unit, or other sulfur removal technology unit as known to
those skilled in the art. Further, its location in the process may
be moved to achieve different product purity requirements. Sulfur
depleted stream 38 is then sent to catalytic oxidation unit 40 for
hydrogen removal. Catalytic oxidation unit 40 can be any type of
known reactor for removing hydrogen in an oxidation type reaction.
In such catalytic oxidation units, oxygen and hydrogen molecules
typically react to form water at elevated temperatures. In the
catalytic oxidation process, air is the oxidant used in the process
as is shown by line 44. Of course, various purities of an oxygen
containing gas can also be used as the oxidant gas. The catalytic
oxidation process enables the hydrogen oxidation to proceed at much
lower temperature (e. g. 250.degree. to 600.degree. C.) than
required for non-catalytic flame-type or similar combustion
processes. The catalysts used in such reactions are typically
precious metal such as palladium or platinum. Catalytic oxidation
units are commercially available and are well known in the
field.
[0043] Hydrogen lean stream 42 now exits catalytic oxidation unit
40 and is preferably sent to CO2 removal unit 50 in which any
residual carbon dioxide is removed in a third carbon dioxide
separation step to produce third carbon dioxide rich stream 52 and
saturated light gas stream 54. Third carbon dioxide rich stream 52
comprising substantially all of the remaining CO2 from hydrogen
lean stream 42 and having typically a purity of over about 99% is
discharged from CO2 removal unit 50 and sent to recompression unit
100 before being sent to compression unit 18. Although shown
separately, it is possible that compression unit 100 and
compression unit 18 can be combined into one unit. Further, it
should be noted that streams 22, 32, and 52 are typically
compressed from different pressures and several possible
compression arrangements can exist depending on optimization and
recovery requirements as known to those skilled in the art. CO2
removal unit 50 can use any of the known carbon dioxide removal or
separation systems including adsorption into suitable liquids,
typically amines, or mechanical separation processes for separating
gases using permeable membrane technology. Preferred carbon dioxide
removal systems are amine gas treatments, also known as gas
treating, gas sweetening or acid gas removal. Amine gas treatments
refers to a group of processes that use aqueous solutions of
various alkylamines (commonly referred to simply as amines) to
remove hydrogen sulfides and carbon dioxide from gas streams. Such
units are well known and commercially available. As shown in this
embodiment, carbon dioxide stream 76 which includes the combined
compressed carbon dioxide product streams may be returned to the
source for use in a number of applications and particularly for
enhanced oil recovery.
[0044] At this point of the process, a bypass valve (not shown) can
be incorporated into third light gas enriched stream 54 to bypass
additional processing with third light gas enriched stream 54 being
used as an additional fuel source, recovered for further
processing, or vented if the only goal of the process is carbon
dioxide purification. Of course, if the purpose of the present
process is to upgrade and recover high grade carbon dioxide, no
additional process equipment is needed and the process would end
with the recovery of third carbon dioxide rich stream 52 which is
combined with the earlier carbon dioxide rich streams, as desired,
resulting in a high grade carbon dioxide product stream. If
additional recovery of the light gas fraction is desired, as shown
in the embodiment in FIG. 1, third light gas enriched stream 54 is
sent for further processing as described below.
[0045] To recover at least one additional light fraction gas, and
preferably helium in accordance with this embodiment, third light
gas enriched stream 54 containing the remaining light gas
components including one or more of the rare gases, nitrogen and
traces amounts of residual hydrocarbons is dried in dryer 56 and
dried light gas stream 58 is sent to cryogenic distillation unit 60
for further separation. As understood by the skilled person, dried
light gas stream 58 will be a small volume, typically less than
about 15% of the volume of feed stream 2. Thus the further
processing of the remaining light gas components can be conducted
using equipment requiring minimal capital and processing costs.
Cryogenic distillation unit 60 is used to separate the desired
product gas, preferably one or more light gases and more preferably
helium, from the remaining light gases.
[0046] The gas streams leaving cryogenic distillation unit 60 are
referred to for convenience as helium rich stream 62 and byproduct
stream 64 although any other light gas in the light gas fraction
can be recovered using this process and as such recovery is
considered an equivalent embodiment. Byproduct stream 64 is defined
as substantially containing gases with a boiling point higher than
that of helium and lower than that of carbon dioxide. Helium rich
stream 62 will have a purity of more than about 75%, and preferably
more than 85%, and may be sent to helium separation unit 70 which
separates the desired product gas, here helium, from the remaining
lights. It is possible in other embodiments of this invention to
recover helium rich stream 62 which could be compressed and sent to
an offsite facility for further processing and/or purification.
Helium product gas stream 72 will typically be at purities of
greater than about 85%, more preferably at purities of greater than
about 90%, and most preferably at purities of greater than 99.99%
helium by volume. Helium product gas 72 is recovered for future
commercial use.
[0047] The remaining gases and small amounts of non-recovered
helium in waste light fraction stream 74 from helium separation
unit 70 are preferably recompressed in tail gas recompression
compressor 80 and sent to catalytic oxidation unit 40 as shown to
reduce the loss of helium product. One skilled would understand
there are other possible points to reintroduce the recycled stream.
Helium separation unit 70 can be any available separation system,
but will typically be a membrane separation system or a pressure
swing adsorption system. Both membrane and pressure swing
adsorption systems are well known and commercially available.
[0048] Finally, byproduct stream 64 leaving cryogenic distillation
unit 60 can be either vented to atmosphere or sent for recovery. In
a preferred embodiment of the present process, all or part of
byproduct stream 64 is optionally compressed in byproduct
compressor 90 and returned to one or more of the carbon dioxide
streams such as carbon dioxide stream 22 or second carbon dioxide
rich stream 52 to preserve volume of the processed feed stream. One
skilled in the art can see there may be alternative embodiments
with byproduct stream 64 compressed in other compressors depending
upon pressure.
[0049] Finally, in the event that the carbon dioxide
purification/light gas recovery facility shuts down, bypass valve 4
and associated controls are included to ensure that the user of the
carbon dioxide product gas could bypass the facility (process) and
continue to receive gas flow such as in a pipeline operation.
[0050] It should be apparent to one skilled in the art that while
the preferred application of this invention is on naturally
occurring streams containing predominantly carbon dioxide, and
preferably with recoverable rare gases, it could be applied to any
stream containing predominantly carbon dioxide. It should also be
apparent to those skilled in the art that the subject invention is
not limited by the Figure or disclosure provided herein which have
been provided to merely demonstrate the advantages and operability
of the present invention. The scope of this invention includes
equivalent embodiments, modifications, and variations that fall
within the scope of the attached claims.
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