CROSS REFERENCE TO RELATED APPLICATIONS
BACKGROUND
Field of Disclosure
[0003] The disclosure relates generally to the field of natural gas liquefaction to form
liquefied natural gas (LNG). More specifically, the disclosure relates to the production
and transfer of LNG from offshore and/or remote sources of natural gas.
Description of Related Art
[0004] This section is intended to introduce various aspects of the art, which may be associated
with the present disclosure. This discussion is intended to provide a framework to
facilitate a better understanding of particular aspects of the present disclosure.
Accordingly, it should be understood that this section should be read in this light,
and not necessarily as an admission of prior art.
[0005] LNG is a rapidly growing means to supply natural gas from locations with an abundant
supply of natural gas to distant locations with a strong demand for natural gas. The
conventional LNG cycle includes: a) initial treatments of the natural gas resource
to remove contaminants such as water, sulfur compounds and carbon dioxide; b) the
separation of some heavier hydrocarbon gases, such as propane, butane, pentane, etc.
by a variety of possible methods including self-refrigeration, external refrigeration,
lean oil, etc.; c) refrigeration of the natural gas substantially by external refrigeration
to form liquefied natural gas at or near atmospheric pressure and about -160 °C; d)
transport of the LNG product in ships or tankers designed for this purpose to a market
location; and e) re-pressurization and regasification of the LNG at a regasification
plant to form a pressurized natural gas stream that may distributed to natural gas
consumers. Step (c) of the conventional LNG cycle usually requires the use of large
refrigeration compressors often powered by large gas turbine drivers that emit substantial
carbon and other emissions. Large capital investments in the billions of US dollars
and extensive infrastructure are required as part of the liquefaction plant. Step
(e) of the conventional LNG cycle generally includes re-pressurizing the LNG to the
required pressure using cryogenic pumps and then re-gasifying the LNG to form pressurized
natural gas by exchanging heat through an intermediate fluid but ultimately with seawater
or by combusting a portion of the natural gas to heat and vaporize the LNG. Generally,
the available exergy of the cryogenic LNG is not utilized.
[0006] A relatively new technology for producing LNG is known as floating LNG (FLNG). FLNG
technology involves the construction of the gas treating and liquefaction facility
on a floating structure such as barge or a ship. FLNG is a technology solution for
monetizing offshore stranded gas where it is not economically viable to construct
a gas pipeline to shore. FLNG is also increasingly being considered for onshore and
near-shore gas fields located in remote, environmentally sensitive and/or politically
challenging regions. The technology has certain advantages over conventional onshore
LNG in that it has a lower environmental footprint at the production site. The technology
may also deliver projects faster and at a lower cost since the bulk of the LNG facility
is constructed in shipyards with lower labor rates and reduced execution risk.
[0007] Although FLNG has several advantages over conventional onshore LNG, significant technical
challenges remain in the application of the technology. For example, the FLNG structure
must provide the same level of gas treating and liquefaction in an area that is often
less than a quarter of what would be available for an onshore LNG plant. For this
reason, there is a need to develop technology that reduces the footprint of the FLNG
plant while maintaining the capacity of the liquefaction facility to reduce overall
project cost. One promising means of reducing the footprint is to modify the liquefaction
technology used in the FLNG plant. Known liquefaction technologies include a single
mixed refrigerant (SMR) process, a dual mixed refrigerant (DMR) process, and expander-based
(or expansion) process. The expander-based process has several advantages that make
it well suited for FLNG projects. The most significant advantage is that the technology
offers liquefaction without the need for external hydrocarbon refrigerants. Removing
liquid hydrocarbon refrigerant inventory, such as propane storage, significantly reduces
safety concerns that are particularly acute on FLNG projects. An additional advantage
of the expander-based process compared to a mixed refrigerant process is that the
expander-based process is less sensitive to offshore motions since the main refrigerant
mostly remains in the gas phase.
[0008] Although expander-based process has its advantages, the application of this technology
to an FLNG project with LNG production of greater than 2 million tons per year (MTA)
has proven to be less appealing than the use of the mixed refrigerant process. The
capacity of known expander-based process trains is typically less than 1.5 MTA. In
contrast, a mixed refrigerant process train, such as that of the propane-precooled
process or the dual mixed refrigerant process, can have a train capacity of greater
than 5 MTA. The size of the expander-based process train is limited since its refrigerant
mostly remains in the vapor state throughout the entire process and the refrigerant
absorbs energy through its sensible heat. For these reasons, the refrigerant volumetric
flow rate is large throughout the process, and the size of the heat exchangers and
piping are proportionately greater than those used in a mixed refrigerant process.
Furthermore, the limitations in compander horsepower size results in parallel rotating
machinery as the capacity of the expander-based process train increases. The production
rate of an FLNG project using an expander-based process can be made to be greater
than 2 MTA if multiple expander-based trains are allowed. For example, for a 6 MTA
FLNG project, six or more parallel expander-based process trains may be sufficient
to achieve the required production. However, the equipment count, complexity and cost
all increase with multiple expander trains. Additionally, the assumed process simplicity
of the expander-based process compared to a mixed refrigerant process begins to be
questioned if multiple trains are required for the expander-based process while the
mixed refrigerant process can obtain the required production rate with one or two
trains. For these reasons, there is a need to develop an FLNG liquefaction process
with the advantages of an expander-based process while achieving a high LNG production
capacity. There is a further need to develop an FLNG technology solution that is better
able to handle the challenges that vessel motion has on gas processing.
[0009] United States Patent No.
3,400,547 to Williams et al. discloses a process within an LNG production facility where liquid nitrogen (LIN)
produced at a different location is used as a refrigerant to liquefy natural gas.
The process uses propane chillers to cool the natural gas prior to condensing the
natural gas by indirect heat exchange with the vaporizing LIN.
GB Patent No. 1,596,330 to Thompson discloses a process within an LNG production facility where LIN produced
at a different location is used as the refrigerant to liquefy natural gas. The process
uses propane and ethylene chillers in combination with the LIN to liquefy the natural
gas into LNG. The processes disclosed by these two patents have the disadvantage of
using a mechanical refrigeration system while still requiring a significant of amount
of LIN to produce the LNG. Both processes estimate that for every ton of LNG produced,
approximately one or more tons of LIN is required. In FLNG applications, space for
storage of LIN either topside or in the hull of the floating structure may be limited.
It would be advantageous to have an LNG production technology on an FLNG that uses
LIN since it would significantly reduce the required topside space for the liquefaction
process. Additionally, it would be advantageous to have an LNG production technology
that uses less than 1 ton of LIN, or more preferably less than 0.75 ton of LIN, or
more preferably less than 0.5 ton of LIN, for every ton of LNG produced.
[0010] United States Patent No.
6,412,302 to Foglietta describes a feed gas expander-based process where two independent closed refrigeration
loops are used to cool the feed gas to form LNG. The first closed refrigeration loop
uses the feed gas or components of the feed gas as the refrigerant. Nitrogen gas is
used as the refrigerant for the second closed refrigeration loop. This technology
has an advantage of requiring smaller equipment and topside space than a dual loop
nitrogen expander-based process. For example, the volumetric flow rate of the refrigerant
into the low pressure compressor can be 20 to 50% smaller for this technology compared
to a dual loop nitrogen expander-based process. The technology, however, is still
limited to a capacity of less than 1.5 MTA.
[0011] United States Patent No.
8,616,012 to Minta describes a feed gas expander-based process where feed gas is used as the refrigerant
in a closed refrigeration loop. Within this closed refrigeration loop, the refrigerant
is compressed to a pressure greater than or equal to 1500 psia, or more preferably
greater than 2500 psia. The refrigerant is then cooled and expanded to achieve cryogenic
temperatures. This cooled refrigerant is then used in a heat exchanger to cool the
feed gas from warm temperatures to cryogenic temperatures. A subcooling refrigeration
loop is then employed to further cool the feed gas to form LNG. In one embodiment,
the subcooling refrigeration loop is a closed loop with flash gas used as the refrigerant.
This feed gas expander-based process has the advantage of not being limited to a train
capacity range of less than 1 MTA. A train size of approximately 6 MTA has been considered.
However, the technology has the disadvantage of a high equipment count and increased
complexity due to its requirement for two independent refrigeration loops and the
compression of the feed gas. Furthermore, the high pressure operation also means that
the equipment and piping will be much heavier than that of other expander-based processes.
[0012] GB Patent No. 2,486,036 to Maunder et al. describes a feed gas expander-based process that is an open loop refrigeration cycle
including a precooling expander loop and a liquefying expander loop, where the gas
phase after expansion is used to liquefy the natural gas. According to Maunder, including
a liquefying expander in the process significantly reduces the recycle gas rate and
the overall required refrigeration power. This technology is simpler than the technologies
described by Foglietta and Minta since only one type of refrigerant is used with a
single compression string. However, the technology is still limited to capacity of
less than 1.5 MTA and it requires the use of a liquefying expander, which is not standard
equipment for LNG production. The technology has also been shown to be less efficient
than the technologies described by Foglietta and Minta for the liquefaction of lean
natural gas.
GB Patent No. 2470062 describes a method for producing liquefied natural gas according to the preamble
of claim 1.
[0013] There remains a need to develop an LNG production process with the advantages of
an expander-based process while having a high LNG production capacity with a reduced
facility footprint. There is a further need to develop an LNG technology solution
that is better able to handle the challenges that vessel motion has on gas processing.
Such a high capacity expander-based liquefaction process would be particularly suitable
for FLNG applications where the inherent safety and simplicity of expander-based liquefaction
processes are greatly valued.
SUMMARY
[0014] The present invention provides a method for producing liquefied natural gas (LNG)
according to claim 1. A natural gas stream is directed to a mechanical refrigeration
unit to liquefy the natural gas stream and form a pressurized liquefied natural gas
(LNG) stream with a pressure greater than 50 psia (345 kPa) and less than 500 psia
(3445 kPa). A liquid refrigerant subcooling unit is provided at a first location.
Liquid refrigerant is produced at a second location that is geographically separate
from the first location. The produced liquid refrigerant is transported to the first
location. The pressurized LNG stream is subcooled in the liquid refrigerant subcooling
unit by exchanging heat between the pressurized LNG stream and at least one stream
of the liquid refrigerant to thereby produce an LNG stream.
[0015] The foregoing has broadly outlined the features of the present disclosure so that
the detailed description that follows may be better understood. Additional features
will also be described herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] These and other features, aspects and advantages of the disclosure will become apparent
from the following description, appending claims and the accompanying drawings, which
are briefly described below.
Figure 1 is a graph showing a temperature cooling curve for an expander-based heat
exchanger process.
Figure 2A is a simplified diagram of the value chain of known FLNG technology.
Figure 2B is a simplified diagram of the value chain of the disclosed aspects.
Figure 3 is a schematic diagram of a method according to the current invention.
Figure 4 is a schematic diagram of a mechanical refrigeration unit according to disclosed
aspects.
Figure 5 is a schematic diagram of a liquid nitrogen (LIN) subcooling unit according
to disclosed aspects.
Figure 6 is a schematic diagram of a LIN subcooling unit according to disclosed aspects.
Figure 7 is a flowchart showing a method according to disclosed aspects.
[0017] It should be noted that the figures are merely examples and no limitations on the
scope of the present disclosure are intended thereby. Further, the figures are generally
not drawn to scale, but are drafted for purposes of convenience and clarity in illustrating
various aspects of the disclosure.
DETAILED DESCRIPTION
[0018] To promote an understanding of the principles of the disclosure, reference will now
be made to the features illustrated in the drawings and specific language will be
used to describe the same. It will nevertheless be understood that no limitation of
the scope of the disclosure is thereby intended. Any alterations and further modifications,
and any further applications of the principles of the disclosure as described herein
are contemplated as would normally occur to one skilled in the art to which the disclosure
relates. For the sake clarity, some features not relevant to the present disclosure
may not be shown in the drawings.
[0019] At the outset, for ease of reference, certain terms used in this application and
their meanings as used in this context are set forth. To the extent a term used herein
is not defined below, it should be given the broadest definition persons in the pertinent
art have given that term as reflected in at least one printed publication or issued
patent.
[0020] As one of ordinary skill would appreciate, different persons may refer to the same
feature or component by different names. This document does not intend to distinguish
between components or features that differ in name only. The figures are not necessarily
to scale. Certain features and components herein may be shown exaggerated in scale
or in schematic form and some details of conventional elements may not be shown in
the interest of clarity and conciseness. When referring to the figures described herein,
the same reference numerals may be referenced in multiple figures for the sake of
simplicity. In the following description and in the claims, the terms "including"
and "comprising" are used in an openended fashion, and thus, should be interpreted
to mean "including, but not limited to."
[0021] The articles "the," "a" and "an" are not necessarily limited to mean only one, but
rather are inclusive and open ended so as to include, optionally, multiple such elements.
[0022] As used herein, the terms "approximately," "about," "substantially," and similar
terms are intended to have a broad meaning in harmony with the common and accepted
usage by those of ordinary skill in the art to which the subject matter of this disclosure
pertains. It should be understood by those of skill in the art who review this disclosure
that these terms are intended to allow a description of certain features described
and claimed without restricting the scope of these features to the precise numeral
ranges provided. Accordingly, these terms should be interpreted as indicating that
insubstantial or inconsequential modifications or alterations of the subject matter
described and are considered to be within the scope of the disclosure.
[0023] The term "heat exchanger" refers to a device designed to efficiently transfer or
"exchange" heat from one matter to another. Exemplary heat exchanger types include
a cocurrent or counter-current heat exchanger, an indirect heat exchanger (e.g. spiral
wound heat exchanger, plate-fin heat exchanger such as a brazed aluminum plate fin
type, shell-and-tube heat exchanger, etc.), direct contact heat exchanger, or some
combination of these, and so on.
[0024] The term "dual purpose carrier" refers to a ship capable of (a) transporting LIN
to an export terminal for natural gas and/or LNG and (b) transporting LNG to an LNG
import terminal.
[0025] As previously described, the conventional LNG cycle includes: (a) initial treatments
of the natural gas resource to remove contaminants such as water, sulfur compounds
and carbon dioxide; (b) the separation of some heavier hydrocarbon gases, such as
propane, butane, pentane, etc. by a variety of possible methods including self-refrigeration,
external refrigeration, lean oil, etc.; (c) refrigeration of the natural gas substantially
by external refrigeration to form LNG at or near atmospheric pressure and about -160
°C; (d) transport of the LNG product in ships or tankers designed for this purpose
to a market location; and (e) re-pressurization and regasification of the LNG at a
regasification plant to form a pressurized natural gas stream that may distributed
to natural gas consumers. The present disclosure generally involves liquefying natural
gas using liquid nitrogen (LIN). In general, using LIN to produce LNG is a non-conventional
LNG cycle in which step (c) above is replaced by a natural gas liquefaction process
that uses a significant amount of LIN as an open loop source of refrigeration, and
in which step (e) above may be modified to use the exergy of the cryogenic LNG to
facilitate the liquefaction of nitrogen gas to form LIN that may then be transported
to the resource location and used as a source of refrigeration for the production
of LNG. The disclosed LIN-to-LNG concept may further include the transport of LNG
in a ship or tanker from the resource location (export terminal) to the market location
(import terminal) and the reverse transport of LIN from the market location to the
resource location.
[0026] Aspects disclosed herein provide a method for enhancing a mechanical refrigeration
process for the production of LNG using liquid refrigerant produced at a different
location to subcool the liquefied natural gas coming from the mechanical refrigeration
process. More specifically, a process is described in which treated natural gas may
be directed to a mechanical refrigeration process. The natural gas may be completely
liquefied within the mechanical refrigeration process to produce a pressurized LNG
stream where the pressure of the pressurized LNG stream is greater than 50 psia (or
345 kPa) and less than 500 psia (or 3445 kPa), or more specifically greater than 100
psia (or 690 kPa) and less than 400 psia (or 2758 kPa), or more specifically greater
than 200 psia (or 1379 kPa) and less than 300 psia (or 2068 kPa). The pressurized
LNG stream may then be subcooled by exchanging heat with at least one liquid refrigerant
stream to form an LNG stream. The liquid refrigerant stream is produced at a different
geographic location than the location where the natural gas is liquefied, and may
be 50 miles, or 100 miles, or 200 miles, or 500 miles, or 1,000 miles, or more than
1,000 miles from such location. The mechanical refrigeration process may be a single-mixed
refrigerant process, a pure component cascade refrigerant process, a dual-mixed refrigerant
process, an expander-based refrigeration process, or any other commonly known refrigeration
process that can liquefy a natural gas stream to produce a pressurized LNG stream.
[0027] In an aspect, an expander-based process for the production of LNG may be enhanced
by using LIN produced at a different location to subcool the pressurized LNG coming
from the expander-based process. Natural gas may be treated to remove impurities,
if present, such as water, heavy hydrocarbons, and sour gases, to make the natural
gas suitable for liquefaction. The treated natural gas may be completely liquefied
within the expander-based process to produce a pressurized LNG stream where the pressure
of the pressurized LNG stream is greater than 50 psia (or 345 kPa) and less than 500
psia (or 3445 kPa), or more specifically greater than 100 psia (or 690 kPa) and less
than 400 psia (or 2758 kPa), or more specifically greater than 200 psia (or 1379 kPa)
and less than 300 psia (or 2068 kPa). The pressurized LNG stream may then be subcooled
by exchanging heat with at least one LIN stream to form an LNG stream. The expander-based
process may be a nitrogen gas expander-based process or may be a feed gas expander-based
process.
[0028] Figure 1 shows a typical temperature cooling curve
100 for an expander-based liquefaction process. The higher temperature curve
104 is the temperature curve for the natural gas stream. The lower temperature curve
102 is the composite temperature curve of a cold cooling stream and a warm cooling stream.
As illustrated, the cooling curve is marked by three temperature pinch-points. The
lowest temperature pinch-point
106 occurs where the colder of the two cooling streams, typically the cold cooling stream,
enters the heat exchanger. The intermediate temperature pinch-point
108 occurs where the second cooling stream, typically the warm cooling stream, enters
the heat exchanger. The warm temperature pinch-point
110 occurs where the cold and warm cooling streams exit the heat exchanger. The lowest
temperature pinch-point
106 sets the required flow rate of the cold cooling stream. Since the cold cooling stream
is first cooled by the warm cooling stream prior to being expanded to the low temperature,
the flow rate of the cold cooling stream also impacts the required flow rate of the
warm cooling stream. One way to increase the capacity of the expander-based process
without significantly increasing equipment size and required power is to increase
the temperature of lowest temperature pinch point. In such a case, to produce LNG
additional refrigeration is needed to subcool the pressurized LNG coming from the
expander-based process. It would not be advantageous nor efficient to subcool the
pressurized LNG with another mechanical refrigeration cycle. For this reason, aspects
described herein propose the use of a liquid refrigerant produced at a different location
to subcool the pressurized LNG. The liquid refrigerant may be LIN.
[0029] Under certain circumstances, the liquid refrigerant can be produced with an amount
of energy that makes the overall process of producing the pressurized LNG and liquefied
refrigerant more thermodynamically efficient than a conventional LNG production process.
For example, the refrigerant may be nitrogen produced from an air separation plant,
where the nitrogen is liquefied using the cold available from the gasification of
LNG. Typically during the gasification of LNG all the available exergy from gasifying
the LNG is lost to the environment. Using this exergy can result in the production
of LIN at a sufficiently low energy cost to make the overall energy requirement of
the disclosed aspects comparable to or even less than the energy costs of a conventional
LNG production process.
[0030] According to the disclosed aspects, the expander-based process may be a feed-gas
expander-based process. The feed-gas expander-based process may be an open loop feed
gas process where the recycling loop comprises a warm-end expander loop and a cold-end
expander loop. The warm-end expander may discharge a first cooling stream and the
cold-end expander may discharge the second cooling stream. The temperature of the
first cooling stream may be higher than the temperature of the second cooling stream.
The pressure of the first cooling stream may be the same or similar to the pressure
of the second cooling stream. The cold-end expander may discharge a two-phase stream
that is separated into a second cooling stream and a second pressurized LNG stream.
Natural gas may be treated to remove impurities, if present, such as water, heavy
hydrocarbons, and sour gases, to make the natural gas suitable for liquefaction. The
treated natural gas may be completely liquefied by indirect exchange of heat with
the first cooling stream and the second cooling stream to produce a first pressurized
LNG stream. The first pressurized LNG stream may be mixed with the second pressurized
LNG stream to form a pressurized LNG stream. The pressure of the pressurized LNG stream
is greater than 50 psia (or 345 kPa) and less than 500 psia (or 3445 kPa), or more
specifically greater than 100 psia (or 690 kPa) and less than 400 psia (or 2758 kPa),
or more specifically greater than 200 psia (or 1379 kPa) and less than 300 psia (or
2068 kPa). The pressurized LNG stream may be subcooled by exchanging heat with at
least one LIN stream to form an LNG stream. The subcooling process may include the
use of at least one heat exchanger to allow for indirect heat exchange between the
vaporizing LIN stream and the pressurized LNG stream. The subcooling process may additionally
comprise other equipment such as compressors, expanders, separators and/or other commonly
known equipment, to facilitate the cooling of the pressurized LNG stream. The vaporized
LIN stream, after heat exchange with the pressurized LNG stream, may be used to liquefy
a second stream of treated natural gas to produce an additional pressurized LNG stream.
The additional pressurized LNG stream may be mixed with the pressurized LNG stream
prior to the subcooling of the pressurized LNG stream with LIN.
[0031] In one disclosed aspect, the produced LNG may be loaded onto an LNG carrier and/or
a dual-purpose carrier at the LNG production location and is transported to an import
terminal at a different location where LNG is offloaded and regasified. The cold energy
from the gasification of the LNG may be used to liquefy nitrogen that is then loaded
onto a LIN carrier and/or a dual-purpose carrier and transported back to the LNG production
location, where the LIN is used to liquefy the treated natural gas.
[0032] Figures 2A and 2B are simplified diagrams highlighting a difference between the value
chain of the aspects disclosed herein and the value chain of conventional FLNG technology,
where an FLNG facility contains all or virtually all equipment necessary to process
and liquefy natural gas. As shown in Figure 2A, an LNG cargo ship
200a transports LNG from an FLNG facility
202 to a land-based import terminal
204 where the LNG is offloaded and regasified. The LNG cargo ship
200b, now empty of cargo and ballast, returns to the FLNG facility
202 to be re-loaded with LNG. In contrast, the aspects disclosed herein and shown in
Figure 2B provide a floating processing unit (FPU)
206 having a much smaller footprint than the FLNG facility
202 (Figure 2A). Referring to Figure 2B, a LIN cargo ship or a dual purpose ship
208a, loaded with LIN at the import terminal
204, arrives at the FPU
206 and offloads its LIN cargo to storage tanks on and/or within the FPU
206. On the FPU
206 a mechanical refrigeration unit cools the natural gas into a pressurized LNG stream.
The pressurized LNG stream is then subcooled within an LIN subcooling unit on the
FPU
206 to produce LNG. The produced LNG is transported to the LNG cargo ship or the dual
purpose ship
208b. The LNG cargo ship or dual purpose ship
208b, now loaded with LNG, sails to the import terminal
204, where the LNG may be offloaded and regasified. The cold energy from the regasification
of the LNG is used to liquefy nitrogen at the import terminal
204. Nitrogen that is liquefied at the import terminal
204 may be produced at an air separation unit
210. The air separation unit
210 may be part of or within the import terminal
204, or a separate facility from the import terminal
204. The LIN may then be loaded into the LIN cargo ship or dual purpose ship, which returns
to the FPU
206 to repeat the liquefaction process.
[0033] In another aspect, LIN may be used to liquefy LNG boil-off gas from the tanks during
LNG production, transport and/or offloading. In another aspect, LIN and/or vaporized
LIN from the subcooling process may be used to cool inlet air going into the gas turbines
of the mechanical refrigeration process. In another aspect, LIN and/or LIN boil-off
gas may be used to keep the liquefaction equipment cold during turndown or shutdown
of the liquefaction process. In another aspect, nitrogen vapor may be used to derime
the cryogenic heat exchangers during the periods between LNG production. The nitrogen
vapor with contaminants may be vented to the atmosphere.
[0034] Figure 3 is a schematic diagram of a system
300 according to a disclosed aspect. Natural gas may be treated to remove impurities,
if present, such as water, heavy hydrocarbons, and sour gases, to produce a treated
natural gas stream
302 that is suitable for liquefaction. The treated natural gas stream
302 may be directed to a mechanical refrigeration unit
304 where the treated natural gas
302 is completely liquefied to produce a pressurized LNG stream
306. The pressure of the pressurized LNG stream
306 may be greater than 50 psia (or 345 kPa) and less than 500 psia (or 3445 kPa), or
more specifically greater than 100 psia (or 690 kPa) and less than 400 psia (or 2758
kPa), or more specifically greater than 200 psia (or 1379 kPa) and less than 300 psia
(or 2068 kPa). The mechanical refrigeration unit
304 may comprise a single-mixed refrigeration process, a pure component cascade refrigeration
process, a dual-mixed refrigeration process, an expander-based refrigeration process,
or any other commonly known refrigeration process that can liquefy the treated natural
gas stream
302 to a pressurized LNG stream
306. The mechanical refrigeration unit
304 may comprise gas turbines that are used to provide the mechanical power to drive
the compressors within the mechanical refrigeration unit
304. The pressurized LNG stream
306 may be directed to a liquid refrigerant subcooling unit
308 where the pressurized LNG stream
306 is subcooled by exchanging heat with a liquid refrigerant stream
310 to form an LNG stream
312. The liquid refrigerant stream
310 is produced at a different location than the location of the mechanical refrigeration
unit
304 and the liquid refrigerant subcooling unit
308. The liquid refrigerant stream
310, after being vaporized and warmed within the liquid refrigerant subcooling unit
308 exits the liquid refrigerant subcooling unit
308 as a refrigerant gas vent
314. The liquid refrigerant subcooling unit
308 comprises at least one heat exchanger to allow for indirect heat exchange between
the liquid refrigerant stream
310 and the pressurized LNG stream
306. The liquid refrigerant subcooling unit
308 may additionally comprise other equipment such as compressors, expanders, separators
and/or other commonly known equipment, to facilitate the cooling of the pressurized
LNG stream
306. The vaporized liquid refrigerant stream
310, after heat exchange with the pressurized LNG stream
306, may be used to liquefy a second stream of treated natural gas
316 to form an additional pressurized LNG stream. The additional pressurized LNG stream
may be mixed with the pressurized LNG stream
306 prior to the subcooling of the pressurized LNG stream
306 with the liquid refrigerant stream
310 to form the LNG stream
312.
[0035] Figure 4 is an illustration of a mechanical refrigeration unit
400 according to disclosed aspects. The mechanical refrigeration unit
400 includes a feed gas expander-based process. Natural gas to be liquefied by the mechanical
refrigeration unit
400 may be treated to remove impurities, if present, such as water, heavy hydrocarbons,
and sour gases, to produce a treated natural gas stream
402 that is suitable for liquefaction. The treated natural gas stream
402 is mixed with a recycled refrigerant stream
404 using a combining device
403. The combined natural gas stream
405 may then be separated by one or more manifolds, splitters, or other types of separators
406, 408, 409 to produce a second treated natural gas stream
410, a first refrigerant stream
412, a second refrigerant stream
414, and a small treated natural gas stream
415 to be liquefied using a liquid refrigerant, as will be explained herein. The first
refrigerant stream
412 is expanded in a first expander
417 to produce a first cooling stream
416. The first cooling stream
416 enters at least one heat exchanger
418 where it exchanges heat with the second treated natural gas stream
410 and the second refrigerant stream
414 to cool these two streams. The first cooling stream
416, now heated, exits the at least one heat exchanger
418 as a first warm stream
420. The second refrigerant stream
414, after being cooled in the at least one heat exchanger
418, is expanded in a second expander
422 to produce a two-phase stream
424. The pressure of the two-phase stream
424 may be the same or near the same to the pressure of the first cooling stream
416. The two-phase stream
424 may be separated into its vapor component and its liquid component in a two-phase
separator
426 to form a second cooling stream
428 and a second pressurized LNG stream
430. The temperature of the first cooling stream
416 may be higher than the temperature of the second cooling stream
428. The second pressurized LNG stream
430 may be pumped, using a pump
432, to a higher pressure after it has exited the two-phase separator
426. The second cooling stream
428 may enter the at least one heat exchanger
418 where it exchanges heat with the second treated natural gas stream
410 and the second refrigerant stream
414 to cool said streams. The heated second cooling stream exits the at least one heat
exchanger
418 as a second warm stream
434. The second treated natural gas stream
410 may exchange heat with the first cooling stream
416 and the second cooling stream
428 to produce a first pressurized LNG stream
436. The first pressurized LNG stream
436 may be reduced in pressure in a hydraulic turbine
437 or other pressure-reducing device after the first pressurized LNG stream
436 has exited the at least one heat exchanger
418. The first pressurized LNG stream
436 may be mixed with the second pressurized LNG stream
430 to form a combined pressurized LNG stream
438. The pressure of the combined pressurized LNG stream
438 may be greater than 50 psia (or 345 kPa) and less than 500 psia (or 3445 kPa), or
more specifically greater than 100 psia (or 690 kPa) and less than 400 psia (or 2758
kPa), or more specifically greater than 200 psia (or 1379 kPa) and less than 300 psia
(or 2068 kPa). The pressurized LNG stream
438 may be directed to a LIN subcooling unit, as will be further described herein.
[0036] The first warm stream
420 may be combined with the second warm stream
434 in a combining apparatus
440 to form a combined warm refrigerant stream
442. The combined warm refrigerant stream
442 may be compressed in multiple compressor stages to form the recycled refrigerant
stream
404. The compressor stages may include a first compressor stage
444, a second compressor stage
446, and a third compressor stage
448. The first compressor stage
444 may be driven by a gas turbine (not shown). The second compressor stage
446 may be driven solely by the shaft power produced by the first expander
417. The third compressor stage
448 may be driven solely by the shaft power produced by the second expander
422. Coolers
450, 452, and
454 may cool the combined warm refrigerant stream
442 after the first, second, and third compressor stages
444, 446, 448, respectively.
[0037] Figure 5 is a schematic diagram of a LIN subcooling unit
500 according to disclosed aspects. The LIN subcooling unit
500 may be used with the mechanical refrigeration unit
400 depicted in Figure 4. LIN produced at a different location than the location of the
LIN subcooling unit
500 is transported to the location of the LIN subcooling unit
500 and directed to at least one heat exchanger
502 as a LIN stream
504. The LIN stream
504 is vaporized in the at least one heat exchanger
502 by subcooling a pressurized LNG stream
506 (which may be the same as the combined pressurized LNG stream
438 of Figure 4) to produce a vaporized nitrogen stream
508 and an LNG stream
510. The vaporized nitrogen stream
508 may be directed to a secondary heat exchanger
512 to liquefy a treated natural gas stream
514, which may be the same as the small treated natural gas stream
415, to form an additional pressurized LNG stream
516. The additional pressurized LNG stream
516 may be combined with the pressurized LNG stream
506 in a combining apparatus
518 prior to entering the at least one heat exchanger
502. The additional pressurized LNG stream
516 may be reduced in pressure in a hydraulic turbine
520 or other pressure-reducing apparatus prior to being combined with the pressurized
LNG stream
506. The vaporized nitrogen stream
508 is heated by the treated natural gas stream
514 in the secondary heat exchanger
512 to form a nitrogen vent gas
522 that may be vented to the atmosphere or used in other areas of the gas processing
facility in which the LIN subcooling unit
500 is located.
[0038] Figure 6 is a schematic diagram of a LIN subcooling unit
600 according to disclosed aspects. The LIN subcooling unit
600 may be used with the mechanical refrigeration unit
400 depicted in Figure 4. LIN produced at a different location than the location of the
LIN subcooling unit
600 is transported from the different location and directed to the LIN subcooling unit
600 as a LIN stream
602. A pump
604 may pump the LIN stream
602 to a pressure greater than 400 psi to form a high pressure LIN stream
606. The high pressure LIN stream
606 exchanges heat with a pressurized LNG stream
608 (which may be the same as the combined pressurized LNG stream
438 of Figure 4) in at least one heat exchanger
610 to form a first warmed nitrogen gas stream
612. The first warmed nitrogen gas stream
612 may be expanded in a first expander
614 to produce a first additionally cooled nitrogen gas stream
616. The first additionally cooled nitrogen gas stream
616 exchanges heat with the pressurized LNG stream
608 in the at least one heat exchanger
610 to form a second warmed nitrogen gas stream
618.
[0039] The second warmed nitrogen gas stream
618 may indirectly exchange heat with other process streams, for example in a secondary
heat exchanger
619, prior to the second warmed nitrogen gas stream
618 being compressed in one or more compressor stages to form a compressed nitrogen gas
stream
620. As shown in Figure 6, the one or more compressor stages may comprise two compressor
stages, including a first compressor stage
622 and a second compressor stage
624. The second compressor stage
624 may be driven solely by the shaft power produced by the first expander
614. The first compressor stage
622 may be driven solely by the shaft power produced by a second expander
626. After each compression stage, the compressed nitrogen gas stream
620 may be cooled by indirect heat exchange with the environment in coolers
628, 630, respectively. The compressed nitrogen gas stream
620 may be expanded in the second expander
626 to produce a second additionally cooled nitrogen gas stream
632. The second additionally cooled nitrogen gas stream
632 exchanges heat with the pressurized LNG stream
608 in the at least one heat exchanger
610 to form a third warmed nitrogen gas stream
634. The pressurized LNG stream
608 is subcooled by exchanging heat with the high pressure LIN stream
606, the first additionally cooled nitrogen gas stream
616, and the second additionally cooled nitrogen gas stream
632 to form an LNG stream
636. The third warmed nitrogen gas stream
634 may be directed to a tertiary heat exchanger
638 to liquefy a treated natural gas stream
640, which may be the same as the small treated natural gas stream
415 in Figure 4, to form an additional pressurized LNG stream
642. The additional pressurized LNG stream
642 may be combined with the pressurized LNG stream
608 in a combining apparatus
644 prior to the subcooling of the pressurized LNG stream
608 in the at least one heat exchanger
610. The additional pressurized LNG stream
642 may be reduced in pressure in a hydraulic turbine
646 prior to being combined with the pressurized LNG stream
608. The third warmed nitrogen gas stream
634 may be heated by the treated natural gas stream
640 to form a nitrogen vent gas
648 that may be vented to the atmosphere or used in other areas of the gas processing
facility in which the LIN subcooling unit
600 is located. The LIN subcooling unit
600 illustrated in Figure 6 reduces the LIN requirement for subcooling a pressurized
LNG stream by approximately 20 to 25% compared to the LIN subcooling unit
500 illustrated in Figure 5. However, the choice of subcooling units may depend on criteria
such as cost of LIN and available topside space for LIN storage and/or the LIN subcooling
unit itself.
[0040] Figure 7 is a flowchart of a method
700 for producing liquefied natural gas (LNG). At block
702 a natural gas stream is directed to a mechanical refrigeration unit to liquefy the
natural gas stream and form a pressurized liquefied natural gas (LNG) stream with
a pressure greater than 50 psia (345 kPa) and less than 500 psia (3445 kPa). At block
704 a liquid refrigerant subcooling unit is provided at a first location. At block
706 liquid refrigerant is produced at a second location that is geographically separate
from the first location. At block
708 the produced liquid refrigerant is transported to the first location. At block
710 the pressurized LNG stream is subcooled in the liquid refrigerant subcooling unit
by exchanging heat between the pressurized LNG stream and at least one stream of the
liquid refrigerant to thereby produce an LNG stream.
[0041] The steps depicted in Figure 7 are provided for illustrative purposes only and a
particular step may not be required to perform the disclosed methodology. Moreover,
Figure 7 may not illustrate all the steps that may be performed. The claims, and only
the claims, define the disclosed system and methodology.
[0042] The aspects described herein have several advantages over known technologies. For
example, the described aspects may significantly increase the capacity of a conventional
mechanical refrigeration process without significantly increasing required power and
footprint of the mechanical refrigeration process. For example, compared to known
feed gas expander-based processes, the feed gas expander-based process coupled with
LIN subcooling described herein can produced approximately 50% more LNG at an equivalent
mechanical refrigeration power. The amount of LIN needed is approximately 0.26 ton
of LIN for every ton of LNG produced. The reduced amount of LIN makes this technology
particularly suitable for FLNG applications. Using the disclosed aspects, the 50%
extra throughput through the feed gas expander-based process only increases the required
volumetric flow to the low pressure compressor and the cryogenic heat exchanger load
by approximately 10% respectively compared to known feed gas expander technologies.
[0043] It should be understood that the numerous changes, modifications, and alternatives
to the preceding disclosure can be made without departing from the scope of the disclosure.
The preceding description, therefore, is not meant to limit the scope of the disclosure.
Rather, the scope of the invention is to be determined only by the appended claims
and their equivalents. It is also contemplated that structures and features in the
present examples can be altered, rearranged, substituted, deleted, duplicated, combined,
or added to each other.
1. Verfahren zur Produktion von verflüssigtem Erdgas (LNG), bei dem
ein Erdgasstrom (302, 403) zu einer mechanischen Kühleinheit (304) geleitet wird,
um den Erdgasstrom (302, 403) zu verflüssigen und einen druckbeaufschlagten verflüssigten
Erdgas- (LNG)-Strom (306, 438) mit einem Druck von mehr als 50 psia (345 kPa) und
weniger als 500 psia (3445 kPa) zu bilden, wobei die mechanische Kühleinheit (304)
einen Kühlprozess auf Expanderbasis einschließt,
eine Unterkühlungseinheit für flüssiges Kältemittel (308) an einem ersten Ort bereitgestellt
wird,
flüssiges Kältemittel an einem zweiten Ort produziert wird, der geographisch von dem
ersten Ort getrennt ist,
das produzierte flüssige Kältemittel an den ersten Ort transportiert wird, und
der druckbeaufschlagte LNG-Strom (306, 438, 506, 608) in der Unterkühlungseinheit
für flüssiges Kältemittel (308) unterkühlt wird, indem Wärme zwischen dem druckbeaufschlagten
LNG-Strom (306, 438, 506, 608) und mindestens einem Strom (310, 504, 602) des flüssigen
Kältemittels getauscht wird, um einen LNG-Strom (312, 510, 636) und einen verdampften
flüssigen Kältemittelstrom (314, 522, 648) zu produzieren,
das durch die folgenden Schritte gekennzeichnet ist, in denen der verdampfte flüssige
Kältemittelstrom zum Verflüssigen eines zweiten behandelten Erdgasstroms (514, 640)
verwendet wird, um einen zusätzlichen druckbeaufschlagten LNG-Strom (516) zu produzieren,
und
der zusätzliche druckbeaufschlagte LNG-Strom (516, 642) mit dem druckbeaufschlagten
LNG-Strom (506, 608) gemischt wird, bevor der druckbeaufschlagte LNG-Strom (506, 608)
mit dem flüssigen Kältemittel unterkühlt wird.
2. Verfahren nach Anspruch 1, bei dem die Unterkühlungseinheit für flüssiges Kältemittel
(308) mindestens einen Wärmetauscher (502, 610) oder mindestens einen Kompressor und/oder
Expander umfasst.
3. Verfahren nach einem der Ansprüche 1 bis 2, das des Weiteren erneutes Verflüssigen
von LNG-Abdampfgas unter Verwendung des flüssigen Kältemittels umfasst.
4. Verfahren nach einem der Ansprüche 1 bis 3, bei dem das flüssige Kältemittel und/oder
ein Abdampfgas des flüssigen Kältemittels verwendet wird bzw. werden, um die mechanische
Kühleinheit (304) und/oder die Gerätschaften der Unterkühlungseinheit für flüssiges
Kältemittel während Teillast- und/oder Abschaltperioden der mechanischen Kühleinheit
(304) kalt zu halten.
5. Verfahren nach einem der Ansprüche 1 bis 4, bei dem warmer Dampf des flüssigen Kältemittels
verwendet wird, um Reif von Wärmetauschern zu entfernen, die zum Wärmetausch verwendet
werden.
6. Verfahren nach einem der Ansprüche 1 bis 5, bei dem des Weiteren:
der LNG-Strom in einem Zweizweck-Frachter (208a, 208b) von dem ersten Ort zu dem zweiten
Ort transportiert wird, und
nachdem der LNG-Strom von dem Zweizweck-Frachter (208a, 208b) abgeladen worden ist,
das flüssige Kältemittel in dem Zweizweck-Frachter (208a, 208b) von dem zweiten Ort
zu dem ersten Ort transportiert wird.
7. Verfahren nach einem der Ansprüche 3 bis 6, bei dem die mechanische Kühleinheit (304)
einen von einem Prozess mit einzeln gemischtem Kältemittel, einem Prozess mit Reinkomponenten-Kaskadenkältemittel
oder einem Prozess mit doppelt gemischtem Kältemittel einschließt.
8. Verfahren nach einem der Ansprüche 1 bis 7, bei dem der druckbeaufschlagte LNG-Strom
(306, 438, 506, 608) einen Druck von mehr als 100 psia (690 kPa) und weniger als 400
psia (2758 kPa) aufweist.
9. Verfahren nach einem der Ansprüche 1 bis 8, bei dem der druckbeaufschlagte LNG-Strom
(306, 438, 506, 608) einen Druck von mehr als 200 psia (1379 kPa) und weniger als
300 psia (2068 kPa) aufweist.
10. Verfahren nach einem der Ansprüche 1 bis 9, bei dem das flüssige Kältemittel flüssigen
Stickstoff (LIN) umfasst, und bei dem des Weiteren der LIN durch Wärmetausch mit LNG
während der erneuten LNG-Vergasung produziert wird.
11. Verfahren nach einem der Ansprüche 1 bis 10, bei dem des Weiteren:
druckbeaufschlagte LNG-Ströme aus einer Vielzahl von mechanischen Kühleinheiten (304)
zu der Unterkühlungseinheit für flüssiges Kältemittel (308) geleitet werden, um mindestens
einen LNG-Strom zu produzieren.