U.S. patent number 3,763,658 [Application Number 05/002,447] was granted by the patent office on 1973-10-09 for combined cascade and multicomponent refrigeration system and method.
Invention is credited to Lee S. Gaumer, Jr., Charles L. Newton.
United States Patent |
3,763,658 |
Gaumer, Jr. , et
al. |
October 9, 1973 |
COMBINED CASCADE AND MULTICOMPONENT REFRIGERATION SYSTEM AND
METHOD
Abstract
A refrigeration system and method are disclosed for liquefying a
feed stream by first subjecting the feed stream to heat exchange
with a single component refrigerant in a closed, cascade cycle and,
thereafter, subjecting the feed stream to heat exchange with a
multicomponent refrigerant in a multiple zone heat exchanger
forming a portion of a second, closed refrigerant cycle.
Inventors: |
Gaumer, Jr.; Lee S. (Allentown,
PA), Newton; Charles L. (Allentown, PA) |
Family
ID: |
21700811 |
Appl.
No.: |
05/002,447 |
Filed: |
January 12, 1970 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
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825526 |
May 19, 1969 |
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Current U.S.
Class: |
62/612; 62/510;
62/335 |
Current CPC
Class: |
F25J
1/0216 (20130101); F25J 1/0052 (20130101); F25J
1/0087 (20130101); F25J 1/0022 (20130101); F25J
1/0292 (20130101); F25J 1/0055 (20130101); F25J
1/0249 (20130101); F25J 1/025 (20130101); F25J
2205/60 (20130101); F25J 2220/68 (20130101); F25J
2220/60 (20130101); F25J 2220/64 (20130101) |
Current International
Class: |
F25J
1/00 (20060101); F25J 1/02 (20060101); F25j
001/00 (); F25j 001/02 (); F25j 005/00 () |
Field of
Search: |
;62/9,11,23,24,27,28,36,40 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Yudkoff; Norman
Assistant Examiner: Purcell; Arthur F.
Parent Case Text
CROSS REFERENCE
The present application is a continuation-in-part of application
Ser. No. 825,526 filed May 19. 1969 and now abandoned.
Claims
Having described one preferred embodiment of the present invention,
what is claimed is:
1. A method of totally liquefying a gaseous, methane-rich feed
stream comprising the steps of:
a. supplying said methane-rich feed stream at a superatmospheric
pressure,
b. precooling said gaseous superatmospheric feed stream to a
temperature within the range of 0.degree.F to -50.degree.F in
progressive heat exchange steps with a single component hydrocarbon
refrigerant undergoing vaporization at a plurality of progressively
lower temperatures and pressures,
c. providing a separate and distinct multicomponent refrigerant
including three hydrocarbon components having different boiling
points and a fourth component having a boiling point substantially
below that of methane,
d. compressing said multicomponent refrigerant to a pressure within
the range of 600-1,200 psia,
e. first cooling said compressed multicomponent refrigerant to a
first lower temperature by passing said multicomponent refrigerant
through a compressor after-cooler in heat exchange with a
non-hydrocarbon cooling fluid,
f. partially condensing a substantial portion of said
multicomponent refrigerant by further precooling said
multicomponent refrigerant to a temperature within the range of
0.degree.F to -50.degree.F in progressive heat exchange with a
single component hydrocarbon refrigerant undergoing vaporization at
a plurality of progressively lower pressures and temperatures,
g. phase separating all of said precooled and partially condensed
multicomponent refrigerant to form a single vapor fraction and a
single liquid fraction,
h. subcooling said liquid fraction in heat exchange with itself
after expansion to form a first subcooled liquid fraction,
i. liquefying and subcooling all of said vapor fraction in heat
exchange with said first subcooled liquid fraction, and with itself
after expansion, to form a second subcooled liquid fraction,
j. totally liquefying said precooled methane-rich feed stream by
further cooling said precooled methane-rich feed stream to at least
its liquefaction temperature, at the superatmospheric pressure
thereof, solely by progressive heat exchange steps with said first
and second subcooled liquid fractions undergoing vaporization,
k. returning both of said vaporized liquid fractions for
recompression according to step (d), and
l. expanding said totally liquefied methane-rich feed stream from
the superatmospheric pressure at which it is totally liquefied in
step (j) to a substantially reduced pressure.
2. The method as claimed in claim 1 further including the step of
maintaining the composition of said multicomponent refrigerant so
as to have an average molecular weight within the range of
24-28.
3. The method as claimed in claim 2 further including the step of
maintaining a multicomponent refrigerant composition comprising
2-12 mole percent of nitrogen, 35-45 mole percent of methane, 32-42
mole percent of ethane, and 9-19 mole percent of propane.
4. The method as claimed in claim 1 wherein said precooled
methane-rich feed stream is cooled in step (j) to a subcooled
temperature which is sufficiently below its liquefaction
temperature to maintain substantially all of said feed stream in
liquid phase upon expansion thereof according to step (1).
5. The method as claimed in claim 1 wherein said multicomponent
refrigerant consists of only four components, three of said
components comprising C.sub.1 to C.sub.3 hydrocarbons and the
fourth component being a non-hydrocarbon component having a normal
boiling point substantially below that of methane.
6. The method as claimed in claim 2 wherein said average molecular
weight is maintained in the order of 26.
7. The method as claimed in claim 1 wherein said multicomponent
refrigerant is compressed to a pressure within the range of
725-1,200 psia.
8. A method of liquefying at least the major portion of a gaseous,
methane-rich feed stream comprising the steps of:
a. supplying said methane-rich feed stream at a superatmospheric
pressure,
b. precooling said gaseous, superatmospheric feed stream to a
temperature within the range of 0.degree.F to -50.degree.F in
progressive heat exchange steps with a single component hydrocarbon
refrigerant undergoing vaporization at a plurality of progressively
lower temperatures and pressures,
c. providing a separate and distinct multicomponent refrigerant
including three components comprising C.sub.1 -C.sub.3 hydrocarbons
and one non-hydrocarbon component having a boiling point
substantially below that of methane,
d. maintaining the composition of said multicomponent refrigerant
by maintaining 35-45 mole percent of the C.sub.1 hydrocarbon
component, maintaining 32-43 mole percent of the C.sub.2
hydrocarbon component, maintaining 9-19 mole percent of the C.sub.3
hydrocarbon component, and maintaining 2-12 mole percent of the
non-hydrocarbon component,
e. further maintaining the composition of said multicomponent
refrigerant so as to maintain the average molecular weight of said
multicomponent refrigerant within the range of 24-28,
f. compressing said multicomponent refrigerant to a pressure within
the range of 600-1,200 psia,
g. first precooling said compressed multicomponent refrigerant by
passage through a compressor after-cooler in heat exchange with a
first cooling fluid,
h. partially condensing 30 to 70 percent of said precooled
multicomponent refrigerant by further precooling said
multicomponent refrigerant to a temperature within the range of
0.degree.F to -50.degree.F in heat exchange steps with a single
component hydrocarbon refrigerant undergoing vaporization at a
plurality of progressively lower pressures and temperatures,
i. phase separating all of said precooled and partially condensed
multicomponent refrigerant to form a single vapor fraction and a
single liquid fraction,
j. subcooling said liquid fraction in heat exchange with itself
after expansion to form a first subcooled liquid fraction,
k. liquefying and subcooling all of said vapor fraction in heat
exchange with said first subcooled liquid fraction, and with itself
after expansion, to form a second subcooled liquid fraction,
l. liquefying at least the major portion of said methane-rich feed
stream by further cooling said precooled methane-rich feed stream
to a temperature substantially below minus 200.degree.F solely by
progressive heat exchange with said first and second subcooled
liquid fractions undergoing vaporization,
m. returning both of said vaporized liquid fractions for
recompression according to step (c), and
n. expanding said liquefied methane-rich feed stream to a reduced
pressure for storage.
9. A refrigeration system for totally liquefying a gaseous
methane-rich feed stream at superatmospheric pressure comprising
the combination of:
a. first multi-stage heat exchanger means connected to a source of
a single component refrigerant and to said feed stream for
precooling said feed stream in heat exchange with said single
component refrigerant undergoing vaporization at a plurality of
progressively lower temperatures,
b. means for supplying a separate and distinct multiple component
refrigerant comprising at least three hydrocarbon components having
different boiling points and at least one non-hydrocarbon component
having a boiling point substantially below that of methane,
c. a compressor for compressing said multicomponent refrigerant to
a superatmospheric pressure,
d. a compressor after-cooler connected to said compressor for
cooling said compressed multicomponent refrigerant to a first lower
temperature,
e. second multi-stage heat exchanger means connected to said
after-cooler and to a source of a single component refrigerant for
further cooling said cooled multicomponent refrigerant to a
sufficiently lower temperature to partially condense 30 percent to
70 percent thereof in heat exchange with said single component
refrigerant undergoing vaporization at a plurality of progressively
lower temperatures,
f. a single phase separator connected to said second multi-stage
heat exchanger means for separating said partially condensed
multicomponent refrigerant into a vapor fraction and a condensed
liquid fraction,
g. third heat exchanger means connected to said phase separator and
including expansion means for subcooling said condensed liquid
fraction in heat exchange with itself, after expansion in said
expansion means, to form a first subcooled liquid fraction,
h. fourth heat exchanger means connected to said phase separator
means and including expansion means for liquefying and subcooling
said vapor fraction in heat exchange with said first subcooled
liquid fraction, and with itself after expansion in said expansion
means, to form a second subcooled liquid fraction,
i. fifth heat exchanger means consisting of no more than two stages
for further cooling said precooled feed stream to at least its
liquefaction temperature, at the superatmospheric pressure thereof,
and totally liquefying said precooled feed stream by passing said
feed stream in heat exchange with said first subcooled liquid
fraction undergoing vaporization in the first stage thereof,
followed by passing said feed stream in heat exchange with said
second subcooled liquid fraction undergoing vaporization in the
second stage thereof,
j. conduit means connected to said fifth heat exchanger means and
to said compressor for returning said vaporized first and second
fractions to said compressor as said multicomponent
refrigerant,
k. conduit means connected to said fifth heat exchanger means for
withdrawing said totally liquefied feed stream from said second
stage of said fifth heat exchanger means, and
l. expansion means in said conduit means for expanding said totally
liquefied feed stream to a substantially reduced pressure.
10. A refrigeration system for liquefying at least the major
portion of a gaseous methane-rich feed stream at a superatmospheric
pressure comprising the combination of:
a. first multiple stage heat exchanger means for precooling said
feed stream to a temperature within the range of 0.degree.F to
-50.degree.F in progressive heat exchange with a single component
hydrocarbon refrigerant at a plurality of progressively lower
pressures and temperatures,
b. means for supplying a separate multicomponent refrigerant
including three hydrocarbon components having different boiling
points and one additional component having a boiling point
substantially below that of methane,
c. means for maintaining the composition of said multicomponent
refrigerant with an average molecular weight within the range of
24-28,
d. a compressor for compressing said separate multicomponent
refrigerant to a pressure within the range of 600 to 1,200
psia,
e. a compressor after-cooler connected to said compressor for first
precooling said compressed multicomponent refrigerant,
f. second multiple stage heat exchanger means connected to said
after-cooler for further precooling and partially condensing a
substantial portion of said multicomponent refrigerant in heat
exchange with a single component hydrocarbon refrigerant at a
plurality of progressively lower temperatures and pressures,
g. a single phase separator connected to said second heat exchanger
means for separating said partially condensed multicomponent
refrigerant into a single vapor fraction and a single condensed
fraction,
h. third heat exchanger means connected to said separator and
including expansion means for subcooling said condensed liquid
fraction in heat exchange with itself, after expansion in said
expansion means, to form a first subcooled liquid fraction,
i. fourth heat exchanger means connected to said separator and
including expansion means for liquefying and subcooling said vapor
fraction in heat exchange with said first subcooled liquid
fraction, and with itself after expansion in said expansion means,
to form a second subcooled liquid fraction,
j. fifth heat exchanger means connected to said first heat
exchanger means including first and second stages for further
cooling said feed stream to at least minus 200.degree.F solely by
heat exchange with said first and second subcooled liquid fractions
undergoing vaporization in said first and second stages.
k. passage means connected to the first stage of said fifth heat
exchanger means for returning said first and second vaporized
fractions to said compressor, and
l. expansion means connected to said fifth heat exchanger means for
reducing the pressure of said further cooled feed stream to a
reduced pressure.
11. A refrigeration system for liquefying at least the major
portion of a methane-rich feed stream comprising the combination
of:
a. first and second heat exchanger means for progressively
precooling and partially condensing said feed stream in heat
exchange relationship with a single component hydrocarbon
refrigerant undergoing vaporization at two progressively lower
temperatures,
b. a phase separator separating said partially condensed feed
stream into a vapor fraction and a liquid condensate,
c. a scrub column intermediate said first and second heat
exchangers, means injecting said precooled feed stream from said
first heat exchanger into said scrub column, and means injecting
said liquid condensate into said scrub column as reflux whereby
benzene and other heavy hydrocarbons are removed from said feed
stream,
d. means supplying a separate multicomponent refrigerant comprising
at least three components having different boiling points including
one component having a boiling point substantially below that of
methane,
e. third heat exchanger means for precooling and partially
condensing a substantial portion of said multicomponent refrigerant
in heat exchange with a single component hydrocarbon refrigerant
undergoing vaporization,
f. a phase separator connected to said third heat exchanger means
for separating said partially condensed multicomponent refrigerant
into a vapor fraction and a condensed liquid fraction,
g. fourth heat exchanger means connected to said separator for
subcooling said condensed liquid fraction in heat exchange with
itself after expansion to form a first subcooled liquid
fraction,
h. fifth heat exchanger means connected to said separator for
liquefying and subcooling said vapor fraction in heat exchange with
said first subcooled liquid fraction, and with itself after
expansion, to form a second subcooled liquid fraction, and
i. sixth heat exchanger means for liquefying at least the major
portion of said precooled feed stream in heat exchange with said
first and second subcooled liquid fractions undergoing
vaporization.
12. The refrigeration system as claimed in claim 11 further
including reboiler means operatively connected to said scrub column
for heating a portion of said removed benzene and heavy
hydrocarbons and re-injecting the same into the bottom portion of
said column as reboil fluid.
Description
BACKGROUND OF THE INVENTION
For many years, cascade-type refrigeration cycles have been used to
cool and liquefy feed streams such as natural gas so that is can be
stored or shipped as a liquid instead of as a gas. Such cascade
cycles have commonly included a plurality of individual
refrigerants having decreasing atmospheric boiling points each of
which is circulated in a closed cycle in heat exchange relationship
with the feed stream and with each other. Unfortunately, the use of
such individual refrigerants requires a very large number of
separate heat exchangers, pumps, compressors and associated piping
and valving for the separate, closed loops of each state. Even more
importantly, the cooling curves of individual refrigerants do not
closely match the continuous cooling curve of the feed stream, and
this is of particular importance with respect to the low
temperature end of the cascade system wherein very substantial
amounts of horsepower are wasted by this inherent inefficiency in
such cascade systems.
In an effort to solve the above-indicated disadvantages, new cycles
have been proposed wherein six or more refrigerants are mixed to
form a multicomponent refrigerant which is subjected to multiple
partial condensations and the condensate from each partial
condensation is heat exchanged against the feed stream. Since each
condensate is itself a multicomponent refrigerant, its cooling
curve more closely approaches that of the feed stream, and
significant savings in horsepower can be achieved. At the same time
however, extremely large and complex heat exchangers are required
since individual tube bundles are required for each of the many
condensates, vapor fractions and portions of the feed. In addition,
many phase separators and spray headers are required to handle the
individual fractions resulting from the multiple partial
condensations. Also, the previous use of multicomponent
refrigerants having six or more components has required substantial
sacrifices in efficiency due to the fact that the refrigerant
compressor discharge pressure had to be a compromise between the
widely varying optimum pressure for the highest and lowest boiling
point components of the multicomponent refrigerant.
SUMMARY OF THE INVENTION
The present invention constitutes a substantial improvement over
both the classical cascade-type systems and the prior art
multicomponent systems just described. This is based upon the
discovery that maximum efficiency and minimum capital investment
can be obtained by first cooling the feed stream in a plurality of
stages using the same single component refrigerant at progressively
lower pressures and temperatures, followed by, liquefying and
subcooling the feed stream by heat exchange with a four component
refrigerant in a simplified, two-zone exchanger. Moreover, the
present invention is based upon the use of the same single
component refrigerant to cool and partially condense the
multicomponent refrigerant such that the fractional condensate and
vapor fraction of the multicomponent refrigerant are formed
independently of the heat exchange functions occurring in the main
exchanger. That is, contrary to the prior art systems, the
multicomponent refrigerant is not subjected to heat exchange with
itself to form successive fractions. As a result, the complexity
and cost of the complete refrigeration system is greatly reduced
while, at the same time, achieving all of the thermodynamic
benefits of having very closely matched cooling curves. In
addition, the use of only four components in the multicomponent
refrigerant results in a refrigerant of relatively low average
molecular weight, and permits the use of a much higher,
substantially more efficient compressor discharge for the
multicomponent refrigerant.
BRIEF DESCRIPTION OF THE DRAWINGS
The FIGURE of the drawings is a schematic, flow diagram of the
complete refrigeration system illustrating one preferred embodiment
of the invention.
DETAILED DESCRIPTION
Referring to the drawing, the natural gas feed stream enters the
system in line 10, after having been freed of carbon dioxide
impurities, and may be at a pressure of 735 psia and a temperature
of approximately 107.degree.F. The feed stream is passed through a
first heat exchanger 12 which forms the first of three, cascade
heat exchangers which are supplied with a single component
refrigerant such as C.sub.2 or C.sub.3 or C.sub.4 hydrocarbon. For
example, it is possible to use any one of ethane, propane,
propylene, butane or halogenated C.sub.2 -C.sub.4 hydrocarbon.
However, it has been found that optimum temperatures may be
obtained at the most ideal pressures by the use of propane as the
single component hydrocarbon refrigerant, and this refrigerant will
be referred to in the remainder of the description.
In the preferred practice of the invention, the natural gas feed
stream is cooled against the propane in exchanger 12 to a first
temperature level in the order of 70.degree.F., and is passed to a
phase separator 14 from which condensed water is removed and
discharged through line 16. While this first temperature level
could be achieved using a higher boiling point refrigerant,
followed by a lower boiling point refrigerant for the subsequently
lower temperature levels, the use of the same single component
refrigerant for achieving all of the precooling temperatures
achieves significant economics as will become more fully
apparent.
The partly dried natural gas feed stream is then passed through
line 18 to one or other of a pair of driers 20 which remove the
remaining moisture from the feed stream. The driers contain a
suitable well known dessicant and are suitably piped and valved so
as to be capable of alternate regeneration as is well known in the
art.
The dried feed stream is then passed through line 22 to a second
single component refrigerant heat exchanger 24 wherein the feed
stream is cooled to approximately 30.degree.F. The cooled feed
stream is then passed through line 26 to benzene scrub column 28
from which benzene and other heavy hydrocarbons are removed as
condensate through discharge line 30. A minor amount of lighter
hydrocarbons including methane, ethane, and propane are also
removed and may be sent to a fractionation system (not shown) so as
to provide make-up referigerants as will be subsequently described.
A major portion of the flow from the bottom of column 28 is
recirculated through a steam reboiler 32 so as to provide vapor to
the bottom trays of the column.
The natural gas feed stream leaves column 28 as overhead vapor and
passes through line 34 to a third single component refrigerant heat
exchanger 36 wherein it is cooled to approximately -29.degree.F.
The feed stream is then passed to a second phase separator 38 from
which additional condensed hydrocarbons are separated and passed
through line 40 back to the benzene column, via pump 42 and line
44, so as to provide reflux for the column. The natural gas feed
stream leaves the top of phase separator 38 as vapor and may
consist of over 90 percent methane at a pressure of approximately
705 psia and at a temperature in the order of -29.degree.F.
The feed stream is then passed through line 46 to one tube circuit
48 of a two zone heat exchanger 50. The feed stream passes upwardly
through tube circuit 48 and is cooled by a counter-flow of a first
multicomponent refrigerant fraction sprayed downwardly over the
tube bundle from spray header 52. This multicomponent refrigerant
portion of the cycle will be hereinafter described in detail
however, it may be noted that the feed stream is cooled to
approximately -170.degree.F by the time it reaches the top of tube
circuit 48 in the first zone. The feed stream then passes directly
into a second tube circuit 54 in the second zone and passes
upwardly through this tube circuit in which it is cooled by second
counterflowing multicomponent refrigerant fraction sprayed
downwardly from spray header 56. The feed stream is withdrawn from
the top of tube circuit 54 as a totally liquid and subcooled stream
having a temperature in the order of -262.degree.F and a pressure
in the order of 650 psia. The liquefied and deeply subcooled feed
stream is then expanded in valve 58 to a pressure in the order of
75 psia and a temperature in the order of -258.degree.F. Because of
the deep subcooling, no flash occurs and the liquid may be
delivered directly to a storage tank in which it may be stored at
atmospheric pressure and a temperature in the order of
-258.degree.F.
Referring back to heat exchangers 12, 24 and 36, the propane, or
other single component refrigerant, is compressed in a compressor
having a first stage 60 and a second stage 62. The compressed
propane is cooled and totally condensed in water cooler 64 and is
expanded in valve 66 before entering heat exchanger 12 at a
temperature in the order of 65.degree.F and a pressure of
approximately 115 psia. Heat exchanger 12, as well as the other
propane exchangers, may be of conventional design as, for example,
having U-tubes submerged in the liquid propane. Thus, a portion of
the liquid propane is vaporized in cooling the feed stream in the
U-tubes and this vapor is returned through line 68 to an
intermediate stage of compressor 62. The remaining liquid
refrigerant from exchanger 12 is passed through line 70 to branch
lines 72 and 90. The portion in branch line 72 is expanded by valve
74 to a pressure in the order of 61 psia and is introduced into
exchanger 24 at a temperature in the order of 25.degree.F. A second
portion of the liquid refrigerant is vaporized in cooling the feed
stream in exchanger 24 and is returned through line 76 to the
suction side of compressor 62. The remaining liquid propane from
exchanger 24 is passed through line 78 and expanded in valve 80 to
a pressure in the order of 18 psia and is introduced into exchanger
36 at a temperature in the order of -35.degree.F. This portion of
the refrigerant is vaporized in cooling the feed stream and the
refrigerant vapor is returned through lines 82 and 84 to the
suction side of compressor 60. Thus, it will be apparent that the
feed stream is successively cooled in three single component
refrigerant heat exchangers wherein the same refrigerant is
utilized at progressively decreasing pressures and temperatures in
a three-stage, cascade refrigerant cycle. Of course, the
temperature of the feed stream at this point is dependent upon the
pressure of the single component refrigerant and the particular
refrigerant which is selected. However, it has been found that the
temperature of the feed stream at this point should be below
32.degree.F, but above -100.degree.F. In addition, it has been
found that the optimum temperature should be between 0.degree.F and
-50.degree.F depending upon the feed stream composition.
In addition to cooling the feed stream in the above described
cascade cycle, the single component refrigerant is also utilized to
cool, and partly condense, the multicomponent refrigerant which is
subsequently utilized to liquefy and subcool the feed stream in
exchanger 50. This cooling of the multicomponent refrigerant by the
single component refrigerant is affected in heat exchanger 86 and
88 by the second portion of the liquid propane from exchanger 12
which is supplied through main line 70 and branch line 90. This
portion of the propane refrigerant is expanded in valve 92 to a
pressure in the order of 61 psia and is introduced into exchanger
86 at a temperature in the order of 25.degree.F. A portion of the
propane is vaporized in cooling the multicomponent refrigerant and
is withdrawn from exchanger 86 through line 87 and is returned to
the suction side of compressor 62. The remaining liquid propane is
passed from exchanger 86 to exchanger 88 via line 93 and expansion
valve 94 such that the propane enters exchanger 88 at a pressure in
the order of 18 psia and at a temperature of approximately
-35.degree.F. This portion is vaporized in partially condensing the
multicomponent refrigerant and the propane vapor is withdrawn and
returned to the suction side of compressor 60 via lines 96 and 84.
Thus, the propane refrigerant portion of the system comprises a
closed cycle wherein the feed stream is cooled by the propane in
exchangers 12, 24 and 36 while the multicomponent refrigerant is
partially condensed in the propane exchangers 86 and 88. In order
to compensate for any loss of refrigerant in the propane cycle, a
make-up line 97 may be provided downstream of valve 66 so that
liquid propane may be added as required. Alternatively, gaseous
propane may be added to suction side of the compressors if liquid
propane is not available.
Reference is now made to the multicomponent refrigerant portion of
the system. While a great many different multicomponent mixtures
could be employed in the above described system, it has been
discovered that very high efficiency is obtained with a mixture
consisting of only four components; namely, nitrogen, methane,
ethane and propane. Furthermore, it has been discovered that the
preferred composition of these four components should comprise 2-12
mole percent of nitrogen, 35- 45 mole percent of methane, 32-42
mole percent of ethane, and 9-19 mole percent of propane. For
example, the optimum refrigerant composition for one particular
natural gas feed stream was found to comprise approximately 10 mole
percent of nitrogen, 40 mole percent of methane, 35 mole percent of
ethane, and 15 mole percent of propane. This refrigerant mixture
was found to have an average molecular weight of 26.30 which is
calculated as follows:
Component Molecular weight .times. Mole percent Nitrogen 28
.times.10 = 280 Methane 16 .times.40 = 640 Ethane 30 .times.35 =
1050 Propane 44 .times.15 = 660 Total molecular weight 2630
2630 total molecular weight/100 = 26,30 average molecular
weight
For slightly different natural gas feed streams, other optimum
refrigerant compositions were found within the above-indicated
ranges of component mole percents. In each case, it was
unexpectedly discovered that the average molecular weight was found
to be between 24 and 28 when using a single component refrigerant
to precool the feed and multicomponent refrigerant prior to heat
exchange therebetween.
Referring back to the drawing, the multicomponent refrigerant is
compressed in compressor stages 100 and 102 having an intercooler
104 and an aftercooler 106. With regard to the pressure of the
compressed multicomponent refrigerant at this point, it has been
discovered that the relatively light molecular weight refrigerant
mixture should be compressed to a higher pressure than that
employed in prior art cycles. That is, it has been found that
substantially increased efficiency results when the relatively
light molecular weight refrigerant is compressed to a pressure
between 500 - 1,200 psia with the optimum range being in the order
of 600 - 1,000 psia. Thus, by way of example, the compressed
multicomponent refrigerant vapor in line 108 may be at a pressure
of 611 psia and a temperature in the order of 107.degree.F. It is
then passed through line 108 to heat exchanger 86 wherein it is
cooled by the propane to approximately 30.degree.F. Thereafter, it
is passed directly through the second propane exchanger 88 from
which it is discharged at a temperature in the order of
-27.degree.F and is passed through line 109 to phase separator 110.
At this point, the multicomponent refrigerant has been partially
condensed such that the liquid condensate in the bottom of
separator 110 preferably comprises about 2 mole percent of
nitrogen, 24 mole percent of methane, 48 mole percent of ethane,
and 26 mole percent of propane. This single-step partial
condensation of the multicomponent refrigerant condenses a
substantial portion of the total refrigerant flow such as, for
example, 30-70 percent by volume per unit time. Accordingly, it is
necessary that the multicomponent refrigerant be precooled to a
temperature substantially below the freezing point of water, and
preferably to a temperature in the order of 0.degree.F to
-100.degree.F. More specifically, it has been found that the
multicomponent refrigerant should be precooled in exchanger 88 to
approximtely the same temperature level as the feed stream in
exchanger 36 which is in the range of 0.degree.F to
-50.degree.F.
Referring back to the drawing, the liquid condensate in separator
110 is passed through line 112 to tube circuit 114 of heat
exchanger 50 wherein it is subcooled to a temperature in the order
of -170.degree.F. This subcooled liquid is expanded in valve 116 to
a pressure in the order of 49 psia, whereby a small portion flashes
to vapor, and its temperature drops to -182.degree.F. This liquid,
and the flashed vapor, is injected into exchanger 50 via line 118
and spray header 52 so as to provide refrigerant flowing downwardly
over tube circuits 48, 122 and 114.
Referring back to phase separator 110, the overhead vapor
preferably has a composition of 20 mole percent nitrogen, 58 mole
percent methane, 19 mole percent ethane, and 3 mole percent
propane. This vapor is passed through line 120 to tube circuit 122
wherein the vapor is cooled and condensed by reason of the
downwardly sprayed refrigerant fraction just described. The
condensed multicomponent refrigerant in tube circuit 122 passes
directly into a second tube circuit 124 wherein it is subcooled to
a temperature in the order of -262.degree.F. This subcooled liquid
fraction is expanded in valve 128 to a pressure in the order of 51
psia whereby a small portion is flashed to vapor and the
temperature drops to approximately -269.degree.F. This liquid and
flashed vapor is injected into exchanger 50 via line 130 and spray
header 56 so as to provide downwardly flowing refrigerant over the
tube circuits 54 and 124. In flowing downwardly over these two tube
circuits, the multicomponent liquid fraction from spray header 56
is vaporized and thereby subcools both the feed stream in circuit
54 and the multicomponent liquid fraction in circuit 124.
Similarly, the multicomponent liquid fraction sprayed from spray
header 52 is vaporized in heat exchange with tube circuits 48, 122,
and 114. As a result, all of the multicomponent refrigerant is
recombined in vapor phase at the bottom of heat exchanger 50 and it
is withdrawn and passed through lines 136 and 138 to the suction
side of compressor 100. Thus, the multicomponent refrigerant
portion of the system forms a separate, closed cycle whereby the
feed stream is most efficiently cooled from the propane level down
to the final subcooled temperature of -262.degree.F.
A make-up line 140 and valve 142 may be provided to add such
multicomponent refrigerant as is required to compensate for
unavoidable losses. As previously mentioned, this make-up
refrigerant may be obtained by fractionating the hydrocarbons
discharged through line 30 from benzene column 28 and adding
additional nitrogen.
From the foregoing description it will be apparent that the present
invention provides a refrigerant cycle in which the feed stream is
progressively cooled first by a plurality of cascade heat
exchangers and secondly by an integral multicomponent heat
exchanger having first and second spray zones or stages wherein the
feed stream is subjected to cooling by progressive vaporization of
two multicomponent liquid fractions. It will also be noted that in
connection with this two-zone multicomponent exchanger, the
multicomponent refrigerant is subjected to only one partial
condensation, namely the partial condensation occurring in heat
exchangers 86 and 88. Thus, the condensate formed in these
exchangers and separated in separator 110 is merely subcooled and
injected into the main heat exchanger 50, while the uncondensed
portion is cooled and subcooled in the main heat exchanger before
it is injected back into the shell side. It will therefore be
apparent that the number of tube circuits, phase separators, and
associated piping and valving is an absolute minimum while, at the
same time, all of the advantages of multicomponent refrigeration
are achieved in liquefying and subcooling the feed.
Lastly, it is to be understood that spray headers 52 and 56 should
be designed for uniform distribution of the multicomponent liquids
and flashed vapors over the tube circuits. Alternatively, a phase
separator may be inserted between valve 116 and header 52, as well
as between valve 128 and header 56 so as to separate the two phase
fluids. In this event, the separated liquids in the bottoms of
these separators may be passed to the respective spray headers, and
the separated vapors are injected into exchanger 50 through lines
(not shown) which enter the exchanger shell immediately adjacent
headers 52 and 56. In either event, both the liquid refrigerant and
the small amount of flashed vapor are injected into the column at
the location of headers 52 and 56.
* * * * *