Ethane recovery or ethane rejection operation
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Solution Overview
Problem
Conventional natural gas processing systems are inefficient when operating outside their design parameters, particularly in processing natural gas with variable composition and throughput rates, and struggle to selectively recover or reject ethane effectively.
Innovation Solution
A natural gas liquids processing system configured with a heat exchanger and a single column having multiple isolated portions, allowing for selective ethane recovery or rejection configurations, where the system can cool and heat streams to control ethane distribution between different portions of the column, optimizing ethane recovery or rejection based on configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional natural gas processing systems are operated outside their design parameters to process natural gas with variable composition and throughput rates, then the system must handle diverse feed conditions, but operational efficiency decreases significantly
Solution Approach 1:
The patent implements dynamic operational flexibility by enabling the processing system to adapt its configuration and operating parameters in real-time based on feed gas composition and throughput requirements. The system can dynamically switch between ethane recovery and ethane rejection modes, and adjust separation parameters to optimize efficiency for varying natural gas compositions from conventional and unconventional sources.
Solution Approach 2:
The system employs parameter changes by modifying operating conditions such as temperature, pressure, and separation parameters to match the specific composition and throughput of the feed gas. This allows the system to maintain high operational efficiency across a wide range of natural gas compositions by adjusting key process parameters rather than requiring fixed design parameters.
2Adaptability or versatility
If conventional natural gas processing systems are designed for ethane recovery, then ethane is separated into the NGL stream, but the system cannot effectively reject ethane to the residue gas stream
Solution Approach 1:
The patent applies universality by designing a single processing system that can perform multiple functions: both ethane recovery into the NGL stream and ethane rejection to the residue gas stream. The system achieves this multi-functionality through configurable operational modes and adjustable separation parameters, eliminating the need for separate dedicated systems for each function.
Solution Approach 2:
The system implements dynamic reconfigurability that allows it to switch between ethane recovery and ethane rejection configurations based on market conditions and feed gas composition. This dynamic capability is achieved through adjustable operational parameters and flexible process control, enabling the system to adapt its separation behavior without physical reconfiguration.
3Productivity
If conventional processing systems operate within narrow parameter ranges, then they maintain design efficiency, but they cannot process natural gas at variable throughput rates
Solution Approach 1:
The patent implements dynamic throughput capability by enabling the system to adjust its processing rate and separation parameters in response to varying feed gas flow rates. The system maintains reliable performance across a wide throughput range through real-time parameter adjustment and flexible operational modes, rather than being constrained to fixed design throughput.
Solution Approach 2:
The system employs parameter changes to maintain performance consistency across variable throughput rates by adjusting temperature, pressure, and separation parameters according to the actual feed rate. This dynamic parameter adjustment ensures that the system operates efficiently and reliably whether processing at high or low throughput levels.
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
The system achieves high propane recovery during ethane rejection (90-99%) and ethane recovery (40-70%), while maintaining flexibility and efficiency across a wide range of natural gas compositions and throughput rates without the need for additional equipment like turbo-expanders.
Implementation Method 1
cooling a feed stream comprising methane, ethane, and propane in a heat exchanger to a temperature below a dew point of a heaviest natural gas liquid component in the feed stream
Implementation Method 2
heating a first portion bottom stream in the heat exchanger to a temperature above a dew point of a heaviest natural gas liquid component in the feed stream
Data Source
AI summary
A method for operating a natural gas liquids processing (NGL) system, the system being selectively configured in either an ethane rejection configuration or an ethane recovery configuration, the method comprising, when the NGL system is in the ethane rejection configuration, collecting a reboiler bottom stream that, in the ethane rejection configuration, includes ethane in an amount of less than 5% by volume, and when the NGL system is in the ethane recovery configuration, collecting a reboiler bottom stream that, in the ethane recovery configuration, includes ethane in an amount of at least about 30% by volume.