Compact Hydrocarbon Gas Processing Assembly for High C2/C3 Recovery
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Solution Overview
Problem
Existing gas processing plants face inefficiencies in recovering C2 and C3 components due to lack of additional rectification and surplus compression capacity, leading to significant losses of desirable hydrocarbons and increased operational costs.
Innovation Solution
A novel process that integrates additional rectification by using a compact arrangement of heat and mass transfer means within a single equipment item, eliminating the need for surplus compression and reducing capital costs, while enhancing recovery efficiency and reducing environmental emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional gas processing plants operate without additional rectification, then capital investment is reduced, but hydrocarbon recovery efficiency deteriorates with significant losses of desirable components
Solution Approach 1:
The patent combines the rectification function with the existing fractionation column by adding a rectification section at the top of the column. This integrates multiple functions (fractionation and rectification) into a single equipment item, improving hydrocarbon recovery without requiring separate standalone rectification equipment, thus limiting the increase in device complexity.
Solution Approach 2:
The fractionation column is divided into distinct sections: a lower fractionation section and an upper rectification section. This segmentation allows each section to perform its specific function optimally while working together as an integrated system, improving overall recovery efficiency without proportionally increasing total complexity.
2Loss of substance
If additional rectification equipment is added to improve separation efficiency, then hydrocarbon recovery improves, but capital costs increase
Solution Approach 1:
The rectification section is merged with the existing fractionation column rather than being built as separate equipment. This allows the plant to gain additional rectification capability using the existing column structure, reducing capital investment compared to adding completely new equipment while still achieving improved hydrocarbon recovery.
3Productivity
If existing plants without surplus compression capacity operate, then capital investment is minimized, but operational efficiency deteriorates with increased power consumption
Solution Approach 1:
The system uses its own internal resources (the fractionation column and existing compression capacity) to perform the rectification function. The existing compression equipment handles the additional load by optimizing its operation, allowing the plant to improve productivity without requiring external surplus compression capacity or incurring excessive power consumption increases.
4Measurement precision
If conventional processes are used without integrated rectification, then device complexity is reduced, but separation precision deteriorates leading to component losses
Solution Approach 1:
The column is segmented into fractionation and rectification sections, with the rectification section providing enhanced separation precision for light hydrocarbon components. This segmentation achieves high measurement precision for component separation while keeping the overall equipment configuration relatively simple by using a single integrated column rather than multiple separate units.
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
Achieves C2 recoveries exceeding 99% and C3 recoveries of 96% without additional power consumption, significantly increasing product recovery and reducing operational costs, with the potential for substantial annual revenue gains.
Implementation Method 1
a first heat and mass transfer means providing heat exchange between the vapor stream and a liquid stream flowing in opposite directions
Implementation Method 2
the rectifying section is configured to condense heavier components arising from the vapor stream to form a liquid stream
Implementation Method 3
an absorbing section below the rectifying section, the absorbing section being configured to absorb lighter components arising from the vapor stream
Implementation Method 4
The liquid stream is expanded through an expansion valve to a pressure slightly above the operating pressure of the fractionation column
Data Source
AI summary
A process and an apparatus are disclosed for a compact processing assembly to improve the recovery of C2 (or C3) and heavier hydrocarbon components from a hydrocarbon gas stream. The preferred method of separating a hydrocarbon gas stream generally includes producing at least a substantially condensed first stream and a cooled second stream, expanding both streams to lower pressure, and supplying the streams to a fractionation tower. In the process and apparatus disclosed, the tower overhead vapor is directed to an absorbing means and a heat and mass transfer means inside a processing assembly. A portion of the outlet vapor from the processing assembly is compressed to higher pressure, cooled and substantially condensed in a heat exchange means inside the processing assembly, then expanded to lower pressure and supplied to the heat and mass transfer means to provide cooling. Condensed liquid from the absorbing means is fed to the tower.