Compact Cryogenic Gas Processing for High C2/C3 Recovery
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Solution Overview
Problem
Conventional cryogenic expansion processes for separating hydrocarbons from natural gas streams suffer from inefficiencies and capital investment costs due to the need for extensive equipment and piping, leading to losses of C2, C3, and heavier hydrocarbon components.
Innovation Solution
A compact processing assembly integrates heat exchange and mass transfer means to combine individual equipment items, reducing capital costs, power consumption, and piping, while enhancing recovery efficiency by ensuring continuous contact between vapors and liquids for improved separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional cryogenic expansion processes are used, then hydrocarbon separation can be achieved, but extensive equipment and piping are required leading to high capital costs and C2, C3 losses
Solution Approach 1:
The patent combines multiple separate equipment items (heat exchangers, separators, expansion machines, and fractionation columns) into a single integrated processing assembly. The heat exchange means, mass transfer means, and separation sections are merged into one compact unit, eliminating the need for extensive external piping and reducing capital costs while maintaining separation efficiency.
2Reliability
If extensive piping and equipment are used, then separation function is provided, but power consumption and capital investment increase
Solution Approach 1:
By merging the heat exchange means, mass transfer means, and separation sections into a single processing assembly, the patent reduces the energy required for pumping and moving fluids between separate equipment items. The integrated design allows for more efficient heat and mass transfer, reducing overall power consumption while maintaining the separation function.
3Ease of manufacture
If individual equipment items are used, then process steps can be performed, but capital costs and operating costs increase
Solution Approach 1:
The patent integrates cooling sections, separation sections, and mass transfer means into a single processing assembly, reducing the number of separate equipment items from multiple standalone units to one compact integrated system. This maintains the ability to perform all necessary process steps while reducing both capital costs and operating costs.
4Productivity
If conventional processes are used, then hydrocarbon recovery can be achieved, but C2, C3, and heavier component losses occur
Solution Approach 1:
The patent employs a mass transfer means that ensures continuous contact between vapors and liquids throughout the processing assembly. This continuous contact maximizes the absorption of C2, C3, and heavier hydrocarbon components into the liquid phase, minimizing losses and improving overall recovery productivity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach achieves C2 recoveries exceeding 95%, C3 recoveries of 95% or more, and nearly complete separation of methane from heavier components at lower energy requirements, with reduced capital and operating costs and minimized environmental emissions.
Implementation Method 1
a heat exchange means configured to cool a feed gas stream to a temperature and pressure condition wherein some of the hydrocarbons in the feed gas stream are condensed into liquid form
Implementation Method 2
some of the hydrocarbons in the feed gas stream are condensed into liquid form
Implementation Method 3
a mass transfer means configured to provide continuous contact between vapors and liquids
Implementation Method 4
The condensed liquid stream is expanded in a work expansion machine or an expansion valve to a lower pressure
Data Source
AI summary
A process and an apparatus are disclosed for the recovery of ethane, ethylene, propane, propylene, and heavier hydrocarbon components from a hydrocarbon gas stream in a compact processing assembly. The gas stream is cooled and divided into first and second streams. The first stream is further cooled to condense substantially all of it and is thereafter expanded to lower pressure and supplied as a feed between first and second absorbing means inside the processing assembly. The second stream is expanded to lower pressure and supplied as the bottom feed to the second absorbing means. A distillation vapor stream is collected from the upper region of the first absorbing means and directed into one or more heat exchange means inside the processing assembly to heat it while cooling the gas stream and the first stream. The heated distillation vapor stream is compressed to higher pressure and divided into a volatile residue gas fraction and a compressed recycle stream. The compressed recycle stream is cooled to condense substantially all of it by the distillation vapor stream in the one or more heat exchange means inside the processing assembly, and is thereafter expanded to lower pressure and supplied as top feed to the first absorbing means. A distillation liquid stream is collected from the lower region of the second absorbing means and directed into a heat and mass transfer means inside the processing assembly to heat it and strip out its volatile components while cooling the gas stream. The quantities and temperatures of the feeds to the first and second absorbing means are effective to maintain the temperature of the upper region of the first absorbing means at a temperature whereby the major portions of the desired components are recovered in the stripped distillation liquid stream.