Integrated Cryogenic Processing Assembly for Hydrocarbon Recovery
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Solution Overview
Problem
Conventional cryogenic expansion processes for natural gas liquids recovery suffer from inefficiencies and capital cost issues due to the need for multiple equipment items and extensive piping, leading to energy consumption and environmental concerns.
Innovation Solution
A compact processing assembly integrates heat exchange and mass transfer functions within a single housing, reducing equipment count, interconnecting piping, and energy consumption while maintaining high recovery rates of hydrocarbon components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional cryogenic expansion processes use multiple equipment items and extensive piping, then hydrocarbon recovery can be achieved, but capital costs and energy consumption increase
Solution Approach 1:
The patent combines multiple separate equipment items (heat exchangers, separators, fractionation columns) into a single integrated processing assembly. The housing contains internal partitions that create distinct chambers for different processing functions, allowing these functions to operate simultaneously in one compact unit rather than requiring multiple separate vessels connected by extensive piping.
Solution Approach 2:
The processing assembly performs multiple functions within a single device: feed gas cooling, liquid-vapor separation, fractionation of hydrocarbons, and product collection. Each partitioned chamber serves a specific function while the overall assembly handles the complete processing sequence that previously required multiple separate equipment items.
2Ease of manufacture
If multiple equipment items and extensive piping are used, then processing functions can be separated, but interconnecting piping increases energy consumption and capital costs
Solution Approach 1:
By integrating all processing functions into one housing with internal partitions, the patent eliminates the need for interconnecting piping between separate equipment items. This removes the energy losses associated with pumping gases and liquids through extensive external piping while maintaining functional separation through the internal partition design.
3Ease of manufacture
If extensive piping with flanged connections is used, then equipment can be assembled, but environmental emissions increase due to potential leaks
Solution Approach 1:
The integrated design with internal partitions eliminates the need for multiple flanged connections between separate equipment items. The single housing contains all processing chambers, removing numerous potential leak points where hydrocarbon emissions could escape to the environment, while still allowing for manufacturing and assembly of the internal partition structure.
4Ease of repair
If conventional processes use separate equipment items, then maintenance can be performed on individual components, but overall system reliability decreases
Solution Approach 1:
The housing is divided into multiple partitioned chambers that can be accessed and maintained separately. Each chamber (cooling section, separation section, fractionation section) can be opened and serviced independently while the other chambers remain operational, maintaining system reliability during maintenance activities.
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 hydrocarbon recovery efficiencies exceeding 99% with reduced power consumption and capital costs, minimizing environmental emissions by eliminating flanged connections and enhancing processing efficiency across a range of pressures and temperatures.
Implementation Method 1
a heat exchange means configured to cool a feed gas stream
Implementation Method 2
with stream 32a leaving the heat exchange means at -30°F
Implementation Method 3
The liquid stream 35 is expanded to a lower pressure by an expansion valve 17
Implementation Method 4
cooling stream 35a to -52°F before it leaves the expansion valve
Implementation Method 5
The expanded stream 38b is supplied to a fractionation tower 18 where it is distilled
Implementation Method 6
to separate residual methane, C2 components, nitrogen, and other volatile components
Implementation Method 7
The remaining portion of the vapor 39 from separator 12 enters a work expansion machine 15
Implementation Method 8
with the work expansion cooling the expanded stream 39a to a temperature of approximately -100°F
Data Source
AI summary
A process and an apparatus are disclosed for a compact processing assembly to recover ethane, ethylene, 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 two absorbing means. The second stream is expanded to lower pressure and supplied as a bottom feed to the lower absorbing means. A distillation liquid stream from the bottom of the lower absorbing means is heated in a heat and mass transfer means to strip out its volatile components. A distillation vapor stream from the top of the heat and mass transfer means is cooled by a distillation vapor stream from the top of the upper absorbing means, thereby forming a condensed stream that is supplied as a top feed to the upper absorbing means.