Natural gas drying method and apparatus
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Solution Overview
Problem
Existing natural gas drying methods using large hygroscopic briquettes are inconsistent and unsatisfactory, and previous patents are limited in their use of calcium chloride prills, which are not effectively utilized in existing dehydration processes.
Innovation Solution
An inline passive dehydration tower with a distribution bed of ceramic beads followed by a drying bed of small calcium chloride prills, increasing the surface area for dehydration and reducing the amount of calcium chloride required, resulting in a more efficient and cost-effective process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of stationary object
If large hygroscopic briquettes are used for natural gas dehydration, then the treatment vessel size is reduced, but the dehydration consistency and adequacy deteriorate
Solution Approach 1:
The invention divides the dehydration bed into two distinct segments: a distribution bed of ceramic beads at the bottom and a drying bed of calcium chloride prills above it. This segmentation allows each layer to perform its specific function optimally - the ceramic beads distribute and pre-condition the gas, while the calcium chloride prills perform the primary dehydration, resulting in consistent and adequate dehydration performance.
Solution Approach 2:
The invention applies different materials with specific local qualities to different zones of the treatment vessel. The ceramic beads in the distribution bed provide structural support and gas distribution, while the calcium chloride prills in the drying bed provide hygroscopic dehydration. This local quality differentiation ensures optimal performance in each zone while maintaining overall system reliability.
2Reliability
If calcium chloride prills are used in existing dehydration processes, then the dehydration effectiveness is improved, but the amount of calcium chloride required increases
Solution Approach 1:
The ceramic beads in the distribution bed perform preliminary actions on the natural gas stream before it reaches the calcium chloride prills. The gas is distributed evenly and pre-conditioned as it passes through the ceramic bead layer, which prepares the gas for more efficient contact with the calcium chloride prills. This preliminary action increases dehydration effectiveness while reducing the total amount of calcium chloride needed.
Solution Approach 2:
The ceramic beads act as an intermediary between the incoming natural gas and the calcium chloride prills. They facilitate even gas distribution and create optimal conditions for the calcium chloride to perform its dehydration function, thereby improving effectiveness while minimizing the quantity of calcium chloride required.
3Area of stationary object
If a distribution bed of ceramic beads followed by calcium chloride prills is used, then the surface area for dehydration is increased, but the device complexity increases
Solution Approach 1:
The invention transitions from using a single-layer horizontal dehydration bed to a two-layer vertical configuration. By stacking the ceramic bead distribution bed below the calcium chloride drying bed, the system increases the effective surface area for dehydration in the vertical dimension. This dimensional change maximizes contact area while maintaining a compact, simple cylindrical vessel structure.
4Productivity
If small calcium chloride prills are used instead of large briquettes, then the dilution rate is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The invention changes the physical parameters of the calcium chloride material from large briquettes to small prills with specific size ranges (0.25-2.0 inches). This parameter change increases the surface area to volume ratio, improving the dilution rate and dehydration productivity. While this requires control over prill size, the specified range provides sufficient tolerance for standard manufacturing processes.
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 process efficiently dries natural gas with a higher dilution rate of calcium chloride, reducing the size of the treatment vessel and initial capital costs, while simplifying operational control and maintenance, producing a consistent dried gas stream and waste water outlet.
Implementation Method 1
a distribution bed of ceramic beads followed by a drying bed of calcium chloride prills
Implementation Method 2
a drying bed of calcium chloride prills that provides a dried outlet gas stream
Implementation Method 3
using a vessel with an internal distribution bed of ceramic beads and a drying bed of calcium chloride prills
Data Source
AI summary
A process and apparatus for dehydrating a wet natural gas feed stream using an inline passive dehydration tower containing a tray supporting a distribution bed of ceramic beads followed by a drying bed of calcium chloride prills that provides a dried outlet gas stream and a waste water outlet.