Compact NGL Recovery Assembly for Efficient C2/C3 Separation
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Solution Overview
Problem
Conventional cryogenic expansion processes for natural gas liquids recovery suffer from inefficiencies, including significant losses of C2, C3, and heavier hydrocarbon components due to incomplete rectification, leading to higher energy consumption and capital costs, as well as environmental concerns from piping leaks.
Innovation Solution
A compact processing assembly integrates heat exchange and mass transfer means within a single unit, reducing equipment count, interconnecting piping, and flanged connections, allowing for higher pressure operation and efficient separation of hydrocarbons with reduced energy requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional cryogenic expansion processes are used for natural gas liquids recovery, then equipment simplicity and operating flexibility are improved, but significant losses of C2, C3, and heavier hydrocarbon components occur due to incomplete rectification
Solution Approach 1:
The patent combines the rectification column and separation equipment into a single integrated processing assembly, where the rectification column is positioned within the separation equipment housing. This merging allows for better integration of the rectification and separation processes, improving hydrocarbon component recovery while maintaining equipment simplicity and operating flexibility.
2Device complexity
If conventional cryogenic expansion processes are used, then process simplicity is improved, but energy consumption increases due to inefficient separation
Solution Approach 1:
The patent merges the rectification column with the separation equipment into one integrated assembly, allowing the processes to work together more efficiently. This integration improves separation efficiency and reduces energy consumption while maintaining process simplicity, as the combined system operates as a unified unit rather than separate interconnected equipment.
3Adaptability or versatility
If multiple separate equipment items are used for heat exchange and mass transfer, then functional versatility is improved, but device complexity and capital costs increase
Solution Approach 1:
The patent combines multiple equipment functions into a single processing assembly where the rectification column is integrated within the separation equipment housing. This merging reduces the number of separate equipment items and interconnecting piping while maintaining all necessary functions for heat exchange and mass transfer, thereby reducing capital costs and device complexity.
Solution Approach 2:
The integrated processing assembly performs multiple functions within a single unit: the rectification column provides mass transfer and separation, while the housing provides structural support and additional separation functionality. This multi-functionality reduces equipment count while maintaining operational versatility.
4Adaptability or versatility
If conventional processes with extensive piping are used, then process flexibility is improved, but environmental emissions increase from piping leaks
Solution Approach 1:
The patent integrates the rectification column within the separation equipment housing, eliminating the need for extensive interconnecting piping between separate equipment items. This merging reduces the number of potential leak points while maintaining process flexibility, thereby reducing environmental emissions from piping leaks.
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%, 100% separation of methane from heavier components, and lower energy consumption, while minimizing environmental emissions and capital costs.
Implementation Method 1
a heat exchange means configured to provide heat exchange between said first portion of said feed stream and a distillation vapor stream arising from said separator section
Implementation Method 2
stream 32 is cooled while further heating the distillation vapor stream, with stream 32a leaving the heat exchange means at −25° F.
Implementation Method 3
The resulting substantially condensed stream 38a at −139° F. is then flash expanded through expansion valve 14 to the operating pressure
Implementation Method 4
During expansion a portion of the stream may be vaporized, resulting in cooling of the total stream
Implementation Method 5
a mass transfer means in said demethanizing section configured to provide mass transfer between a vapor stream and a liquid stream
Implementation Method 6
The remaining portion of the vapor from separator section 118b (stream 39) enters a work expansion machine 15 in which mechanical energy is extracted from this portion of the high pressure feed
Data Source
AI summary
A process and an apparatus are disclosed for a compact processing assembly to recover C2 (or C3) components and heavier hydrocarbon components from a hydrocarbon gas stream. The gas stream is cooled and divided into first and second streams. The first stream is further cooled, expanded to lower pressure, and supplied as a feed between first and second absorbing means. The second stream is expanded to lower pressure and supplied as bottom feed to the second absorbing means. A distillation vapor stream from the first absorbing means is heated, compressed to higher pressure, and divided into a volatile residue gas fraction and a compressed recycle stream. The compressed recycle stream is cooled, expanded to lower pressure, and supplied as top feed to the first absorbing means. A distillation liquid stream from the second absorbing means is heated in a heat and mass transfer means to strip out its volatile components.