Hydrocarbon gas processing
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Solution Overview
Problem
Conventional cryogenic expansion processes for natural gas liquids recovery are inefficient in recovering C2 and C3 components due to lack of additional rectification and require surplus compression capacity, leading to significant losses and increased capital and operating costs.
Innovation Solution
A novel process that integrates additional rectification using a compact heat and mass transfer system, eliminating the need for surplus compression and reducing capital costs by combining equipment into a single housing, thereby enhancing recovery efficiency and reducing power consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional cryogenic expansion processes are used for natural gas liquids recovery, then the process simplicity and ease of operation are maintained, but the recovery efficiency of C2 and C3 components is insufficient leading to significant losses
Solution Approach 1:
The patent combines the rectification function with the heat exchange function by integrating a rectifying section directly into the heat exchanger assembly. This merging of functions allows the system to achieve both cooling and separation in a single integrated unit, improving C2 and C3 component recovery efficiency without requiring separate standalone rectification equipment.
Solution Approach 2:
The patent adds a vertical dimension to the heat exchanger by incorporating a rectifying section with multiple stages arranged vertically. This dimensional addition enables gravity-assisted phase separation and enhanced rectification efficiency, allowing heavier hydrocarbons to settle and lighter components to rise through the structured stages.
2Productivity
If additional rectification equipment is added to improve separation efficiency, then the recovery of C2 and C3 components is improved, but the device complexity and capital costs increase
Solution Approach 1:
The patent merges the rectification function with the existing heat exchange equipment by integrating a rectifying section directly into the heat exchanger assembly. This combination eliminates the need for separate standalone rectification equipment, thereby improving separation efficiency while avoiding the complexity and capital costs associated with adding independent rectification systems.
Solution Approach 2:
The integrated heat exchanger-rectifier assembly performs multiple functions simultaneously: it provides heat exchange for cooling the gas stream and performs rectification for separating hydrocarbon components. This multi-functionality reduces the overall number of equipment items needed in the process, simplifying the system while maintaining high separation efficiency.
3Adaptability or versatility
If surplus compression capacity is installed to handle variable recovery requirements, then the adaptability of the process is improved, but the capital investment and operating costs increase
Solution Approach 1:
The patent implements dynamic control capabilities in the integrated rectification system, allowing operators to adjust recovery settings for different hydrocarbon components based on market conditions and feed gas composition. This dynamic adaptability eliminates the need for surplus compression capacity, as the system can flexibly optimize recovery levels without requiring additional equipment capacity.
4Ease of manufacture
If multiple separate equipment items are used for heat exchange and rectification, then the ease of manufacture and maintenance is improved, but the plot space requirements and piping complexity increase
Solution Approach 1:
The patent combines heat exchange and rectification functions into a single integrated assembly, significantly reducing the plot space required for the facility. By eliminating the need for separate heat exchangers and rectification equipment, the integrated design minimizes spatial requirements while maintaining all necessary manufacturing and maintenance capabilities.
Solution Approach 2:
The rectifying section is nested within the heat exchanger assembly, with the rectification stages positioned inside or adjacent to the heat exchange channels. This nesting arrangement allows both functions to occupy the same physical space, dramatically reducing the overall footprint of the equipment while maintaining full functionality.
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 97% and C3 recoveries of 99%, with significant economic benefits and reduced environmental impact by minimizing piping and potential leak sources, while maintaining efficiency across a range of pressures and temperatures.
Implementation Method 1
The heat and mass transfer means provides heat exchange between a flash expanded stream flowing downward through one pass of the heat and mass transfer means, and a combined vapor stream flowing upward through a second pass of the heat and mass transfer means
Implementation Method 2
The flash expanded stream is further vaporized as it provides cooling and partial condensation of the combined vapor stream
Implementation Method 3
During expansion a portion of the stream is vaporized, resulting in cooling of the total stream
Implementation Method 4
The heat and mass transfer means provides continuous contact between the condensed liquid and the combined vapor stream so that it also functions to provide mass transfer between the vapor and liquid phases
Implementation Method 5
The combined vapor stream is cooled to partial condensation by the flash expanded stream
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.