INTEGRATED MULTICOMPONENT REFRIGERANT AND AIR SEPARATION PROCESS FOR PRODUCING LIQUID OXYGEN

Abstract

A hybrid process of air separation and gas liquefaction, including dividing a compressed multicomponent refrigerant stream into a first portion and a second portion, introducing the first portion into a gas liquefaction system, thereby producing a first multicomponent refrigerant return stream, and introducing the second portion into an air separation system, thereby producing a second multicomponent refrigerant return stream. Wherein the first multicomponent refrigerant return stream and the second multicomponent refrigerant return are recompressed in a common compression system, thereby producing the compressed multicomponent refrigerant stream.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority under 35 U.S.C. § 119 (a) and (b) to US Provisional Patent Application Nos. 63/223,406, filed Sep. 21, 2021 and 63/223,410, filed Jul. 19, 2021, the entire contents of which are incorporated herein by reference.

BACKGROUND

The following abbreviations are used herein: multicomponent refrigerant (MR), air separation unit (ASU), main air compressor (MAC), booster air compressor (BAC), liquefied natural gas (LNG), oxygen (O2), nitrogen (N2), gaseous oxygen (GOX), liquid oxygen (LOX), liquid nitrogen (LIN), liquid argon (LAR), and liquid air (LAIR).

A simple mass and energy balance around the cold end of an ASU (distillation columns+sub-cooler) indicates that the quantity of liquid leaving must be approximately equal to the quantity of liquid entering. Also, for an efficient distillation it is known in the art that the air entering the bottom of the distillation column should be cold vapor near the dew point. Therefore, a simple energy balance requires that a liquid stream (typically LAIR) enter the columns and has a flowrate approximately equal to the sum of the LOX+LIN products.

Prior art schemes utilize only low-pressure air (4 to 7 bara) from the main air compressor to distillation column. Per the above cold end energy balance, liquid air must be leaving cold end of main exchanger and entering the distillation. Condensing at such low-pressure (4 to 7 bara is significantly below the critical pressure of 62 bara) yields very high latent heat of condensation. As the flowrate of the liquid air increases (due to increasing flowrate of LOX+LIN), the heat exchange to produce this LAIR becomes infeasible without vaporizing another stream in the main exchanger to provide additional refrigeration. This is the case particularly when significant quantities of O2 are removed from the process as liquid (LOX) rather than being pumped to higher pressure and vaporized in the main exchanger against the condensing air stream producing high-pressure GOX. Note that the flow of vaporizing MR is already compensated by the condensing of the MR.

In the current application significant quantities of O2 ae removed as LOX rather than vaporizing to produce High-pressure GOX such that at least 80% of oxygen in feed air is produced as liquid oxygen. Or the mass flow of LOX+LIN is greater than mass flow of oxygen in feed air.

Referring now to FIG. 1 (which essentially reproduces the schemes from Praxair patents U.S. Pat. Nos. 6,260,380 and/or 6,112,550), purified feed air stream 101 is cooled by passage through main heat exchanger 102 by indirect heat exchange with return streams and by refrigeration generated by the multicomponent refrigerant fluid circuit as will be more fully described below, and then passed into higher-pressure column 103 which is operating at a pressure generally within the range of from 60 to 200 psia. Within higher-pressure column 103 the feed air is separated by cryogenic rectification into nitrogen-enriched vapor and oxygen-enriched liquid. Nitrogen-enriched vapor is withdrawn from the upper portion of higher-pressure column 103 in stream 104 and condensed in main condenser 105 by indirect heat exchange with boiling oxygen-rich liquid which is lower-pressure column bottom liquid. Resulting nitrogen-enriched liquid 106 is returned to higher-pressure column 103 as reflux and a portion 117 is passed from column to sub-cooler 107 wherein it is subcooled and passed into the upper portion of lower-pressure column 108 as reflux. If desired, a portion 109 of stream 106 may be recovered as product liquid nitrogen. Stream 106 may comprise up to 50 percent of the feed air provided into the system.

Oxygen-enriched liquid is withdrawn from the lower portion of higher-pressure column 103 in stream 110 and passed to sub-cooler 111 wherein it is subcooled. Resulting subcooled oxygen-enriched liquid is then divided into first portion 112 and second portion 113. First portion 112 is passed into lower-pressure column 108 and second portion 113 is passed into argon column condenser 114 wherein it is at least partially vaporized. The resulting vapor is withdrawn from argon column condenser 114 and passed into lower-pressure column 108. Any remaining oxygen-enriched liquid is withdrawn from condenser 114 and then passed into lower-pressure column 108.

Lower-pressure column 108 is operating at a pressure less than that of higher-pressure column 103 and generally within the range of from 15 to 150 psia. Within lower-pressure column 108 the various feeds into that column are separated by cryogenic rectification into nitrogen-rich vapor and oxygen-rich liquid. Nitrogen-rich vapor is withdrawn from the upper portion of lower-pressure column 108 in stream 115, warmed by passage through heat exchangers 102, 111, and 107, and may be recovered as product gaseous nitrogen having a nitrogen concentration of at least 99 mole percent, preferably at least 99.9 mole percent, and most preferably at least 99.999 mole percent. For product purity control purposes, a waste stream 116 is withdrawn from lower-pressure column 108 from a level below the withdrawal point of stream 115, warmed by passage through heat exchangers 102, 111, and 107, and removed from the system. Oxygen-rich liquid is partially vaporized in the lower portion of lower-pressure column 108 by indirect heat exchange with condensing nitrogen-enriched vapor in main condenser 105 as was previously described to provide vapor up-flow for lower-pressure column 108. If desired, a portion of the resulting oxygen-rich vapor may be withdrawn from the lower portion of lower-pressure column 108 in stream 118 having an oxygen concentration generally within the range of from 90 to 99.9 mole percent. Oxygen-rich vapor in stream 118 is warmed by passage through main heat exchanger 102 and recovered as product gaseous oxygen in stream 119. Oxygen-rich liquid is withdrawn from the lower portion of lower-pressure column 108 in stream 120 and recovered as liquid oxygen. Stream 120 may comprise essentially all of the oxygen contained in the feed air.

Fluid comprising oxygen and argon is passed in stream 121 from lower-pressure column 108 into third or argon column 122 wherein it is separated by cryogenic rectification into argon-richer fluid and oxygen-richer fluid. Oxygen-richer fluid is passed from the lower portion of column 122 in stream 123 into lower-pressure column 108. Argon-richer fluid is passed from the upper portion of column 122 as vapor into argon column condenser 114 wherein it is condensed by indirect heat exchange with the aforesaid subcooled oxygen-enriched liquid. Resulting argon-richer liquid is withdrawn from condenser 114. At least a portion of the argon-richer liquid is passed into argon column 122 as reflux and, if desired, another portion is recovered as product liquid argon as shown by stream 124. Stream 124 may comprise effectively all of the argon in the feed air.

There will now be described in greater detail the operation of the multicomponent refrigerant fluid circuit which serves to generate preferably all the refrigeration passed into the cryogenic rectification plant thereby eliminating the need for any turbo-expansion of a process stream to produce refrigeration for the separation, thus decoupling the generation of refrigeration for the cryogenic air separation process from the flow of process streams, such as feed air, associated with the cryogenic air separation process. It should be understood that this is simply one example of a multicomponent refrigerant system, and any alternative system that is known in the art that is suitable for this application may be substituted by one skilled in the art.

The following description illustrates the multicomponent refrigerant fluid system for providing refrigeration throughout the main heat exchanger 102. Multicomponent refrigerant fluid in stream 125 is compressed by passage through recycle compressor 126 to a pressure generally within the range of from 45 to 81400 psia to produce a compressed refrigerant fluid. The compressed refrigerant fluid is cooled of the heat of compression by passage through aftercooler 127 and may be partially condensed. The resulting multicomponent refrigerant fluid 128 is then passed through main heat exchanger 102 wherein it is further cooled and generally is at least partially condensed and may be completely condensed. The resulting cooled, compressed multicomponent refrigerant fluid 129 is then expanded or throttled through valve 130. The throttling preferably partially vaporizes the multicomponent refrigerant fluid, cooling the fluid and generating refrigeration. For some limited circumstances, dependent on heat exchanger conditions, the compressed fluid 129 may be subcooled liquid prior to expansion and may remain as liquid upon initial expansion. Subsequently, upon warming in the heat exchanger, the fluid will have two phases. The pressure expansion of the fluid through a valve would provide refrigeration by the Joule-Thomson effect, i.e. lowering of the fluid temperature due to pressure expansion at constant enthalpy. However, under some circumstances, the fluid expansion could occur by utilizing a two-phase or liquid expansion turbine, so that the fluid temperature would be lowered due to work expansion.

Refrigeration bearing multicomponent two phase refrigerant fluid stream 131 is then passed through main heat exchanger 102 wherein it is warmed and completely vaporized thus serving by indirect heat exchange to cool stream 128 and also to transfer refrigeration into the process streams within the heat exchanger, including feed air stream 101, thus passing refrigeration generated by the multicomponent refrigerant fluid refrigeration circuit into the cryogenic rectification plant to sustain the cryogenic air separation process. The resulting warmed multicomponent refrigerant fluid in vapor stream 125 is then recycled to compressor 126 and the refrigeration cycle starts anew. In the multicomponent refrigerant fluid refrigeration cycle while the high-pressure mixture is condensing, the low-pressure mixture is boiling against it, i.e. the heat of condensation boils the low-pressure liquid. At each temperature level, the net difference between the vaporization and the condensation provides the refrigeration. For a given refrigerant component combination, mixture composition, flowrate and pressure levels determine the available refrigeration at each temperature level.

The multicomponent refrigerant fluid contains two or more components in order to provide the required refrigeration at each temperature. The choice of refrigerant components will depend on the refrigeration load versus temperature for the specific process. Suitable components will be chosen depending upon their normal boiling points, latent heat, and flammability, toxicity, and ozone-depletion potential.

Alternatively, this cold end refrigeration balance can be managed by LIN assist from an external liquefier. In this case the flowrate of LIN assist is approximately equal to the flow rate of LOX production, as described below in FIG. 2. However, this scheme requires the N2 feed to the liquefier be warmed to ambient. This warming and cooling of the N2 feed to the liquefier consumes energy which makes this process inefficient.

Turning now to FIG. 2, the multicomponent refrigerant cycle includes warm multicomponent refrigerant return steam 201, which is at reduced pressure. Warm multicomponent refrigerant return stream 201 has the pressure increased in multicomponent refrigerant compressor 202, thereby producing pressurized multicomponent refrigerant stream 203. Pressurized multicomponent refrigerant stream 203 enters multicomponent refrigerant cooler 204, thereby producing cooled pressurized multicomponent refrigerant stream 205. Cooled, pressurized multicomponent refrigerant stream 205 is introduced to first phase separator vessel 206, which produces first vapor portion 207 and first liquid portion 208.

After passing through liquefaction heat exchanger 209, first vapor portion 207 exits as warmed first vapor stream 242. Warmed first vapor stream 242 is introduced to second phase separator vessel 243, which produces second vapor portion 244 and second liquid portion 245. Second vapor portion 244 is introduced into liquefaction heat exchanger 209. After passing through liquefaction heat exchanger 209 second vapor portion 244 exits as cooled to form at least partially condensed portion 246. Second liquid portion 245 is introduced into liquefaction heat exchanger 209. After passing through liquefaction heat exchanger 209, second liquid portion 245 exits as warm second liquid portion 247.

After passing through liquefaction heat exchanger 209, first liquid portion 208 exits as warmed first liquid stream 248. At least partially condensed portion 246 is introduced into third phase separator vessel 249. Third phase separator vessel 249 produces third vapor portion 250 and third liquid portion 251. Third vapor portion 250 and third liquid portion 251 are combined to form third combined multicomponent refrigerant stream 252, which is introduced into liquefaction heat exchanger 209. After passing through liquefaction heat exchanger 209, third combined multicomponent refrigerant stream 252 exits as warm combined multicomponent refrigerant steam 253.

Warmed second liquid portion 247, warmed first liquid stream 248, and warm combined nitrogen steam 253 are introduced to fourth phase separator vessel 254. Exiting fourth phase separator vessel 254 are fourth vapor portion 255 and fourth liquid portion 256. Fourth vapor portion 255 and fourth liquid portion 256 are combined to form fourth combined multicomponent refrigerant stream 257, which is introduced into liquefaction heat exchanger 209. After passing through liquefaction heat exchanger 209, fourth combined multicomponent refrigerant stream 257 exits as warm multicomponent refrigerant return steam 201.

It is understood, but not shown in FIG. 2, that there will be pressure reducing valves on streams 247, 248, and 246.

Nitrogen refrigeration cycle includes increasing the pressure of first nitrogen recycle stream 210 in low-pressure nitrogen compressor 211, thereby producing warm medium-pressure nitrogen stream 212. Warm medium-pressure nitrogen stream 212 enters first nitrogen cooler 213, thereby producing cooled medium-pressure nitrogen stream 214.

Cooled medium-pressure nitrogen stream 214 is combined with medium-pressure nitrogen stream 240 from ASU 215 and second nitrogen recycle stream 216, thereby producing combined medium-pressure nitrogen stream 217. The pressure of medium-pressure nitrogen stream 217 is increased in medium-pressure nitrogen compressor 218, thereby producing warm intermediate-pressure nitrogen stream 219. Warm intermediate-pressure nitrogen stream 219 enters second nitrogen cooler 220, thereby producing cooled intermediate-pressure nitrogen stream 221.

Cooled intermediate-pressure nitrogen stream 221 is then further compressed in high-pressure nitrogen booster 222, thereby producing high-pressure nitrogen stream 223. High-pressure nitrogen stream 223 then passes through liquefaction heat exchanger 209, after which it is removed at two locations. Typically, first nitrogen refrigeration stream 224 will be removed as a vapor stream, and second nitrogen refrigeration stream 225 will be removed as a liquid stream.

The first location is via first nitrogen refrigeration stream 224, which is then introduced into nitrogen expander 226. Nitrogen expander 276 is connected to high-pressure nitrogen booster 222 by a common drive shaft. After having the pressure reduced in nitrogen expander 226, this stream exits as expanded nitrogen stream 227, which is then introduced into liquefaction heat exchanger 209. Expanded nitrogen stream 227 exits liquefaction heat exchanger 209 as second nitrogen recycle stream 216.

The second location is via second nitrogen refrigeration stream 225, which is then introduced fifth phase separator vessel 228, which produces nitrogen vapor portion 229 and nitrogen liquid portion 230. Nitrogen vapor portion 229 and nitrogen liquid portion 230 are combined to form combined nitrogen stream 231. A portion of combined nitrogen stream 231 is removed as internal liquid nitrogen stream 232. At least a portion 233 of internal liquid nitrogen stream 232 is returned to the ASU, and a portion of internal liquid nitrogen stream 232 may be removed as external LIN product to storage 234. The remaining portion of combined nitrogen stream 231 is introduced into liquefaction heat exchanger 209 as cold nitrogen recycle stream 235. Cold nitrogen recycle stream 235 exits liquefaction heat exchanger 209 as first nitrogen recycle stream 210.

Multicomponent refrigerant cycle and nitrogen refrigeration cycle work together to provide sufficient refrigeration duty to liquefy inlet natural gas stream 236 into liquid natural gas stream 237. In addition, these combined refrigeration streams also provide sufficient additional refrigeration duty via internal liquid nitrogen stream 233, to satisfy the duty requirements of air separation unit 215.

Compressed and purified inlet air stream 238 enters first heat exchanger 239 wherein it exchanges heat with medium-pressure nitrogen stream 240, then enters air separation unit 215. Air separation unit 215 produces at least medium-pressure nitrogen stream 240, and liquid oxygen stream 241. In order to produce the desired flowrate in liquid oxygen stream 241, it is necessary to introduce additional refrigeration duty, in the form of internal liquid nitrogen stream 233.

Medium-pressure nitrogen stream 240 and inlet natural gas stream 236 are introduced into liquefaction heat exchanger 209, as described above. Liquefaction heat exchanger 209 outputs at least liquid natural gas stream 237 and internal liquid nitrogen stream 232. Liquid natural gas stream 237 is then sent to liquid natural gas storage.

To avoid the excessive energy associated with the sensible heat of rewarming and cooling the N2 feed stream to the liquefier, it could be envisioned to send the cold gaseous N2 directly from the medium-pressure column to a cold location in the liquefier. (not warming the gaseous N2 in the ASU). However, in this case the ASU main exchanger heat transfer is imbalanced as the flow of the streams is much higher than the flow of cold streams resulting in unparalleled heat exchange lines as indicated in FIG. 3.

Note, that in FIG. 3 and FIG. 5 the line designated “cold composite” represents the aggregate of the various streams into which heat is being transferred (i.e. “cold” streams), and the line designated “hot composite” represents the aggregate of the various streams from which heat is being transferred (i.e. “hot” streams).

One skilled in the art will recognize that this design of the individual exchanger layers, stacking and manifolding for medium to large scale plant becomes impractical. The prior art arrangement of FIG. 2, wherein such combination of MR, N2 cycle and/or air cycle and NG liquefaction are utilized in a common ASU heat exchanger system, creates significant (and often impractical) complexity in the design and arrangement of main exchanger 209.

SUMMARY

A hybrid process of air separation and gas liquefaction, including dividing a compressed multicomponent refrigerant stream into a first portion and a second portion, introducing the first portion into a gas liquefaction system, thereby producing a first multicomponent refrigerant return stream, and introducing the second portion into an air separation system, thereby producing a second multicomponent refrigerant return stream. Wherein the first multicomponent refrigerant return stream and the second multicomponent refrigerant return are recompressed in a common compression system, thereby producing the compressed multicomponent refrigerant stream.

BRIEF DESCRIPTION OF THE FIGURES

For a further understanding of the nature and objects for the present invention, reference should be made to the following detailed description, taken in conjunction with the accompanying drawings, in which like elements are given the same or analogous reference numbers and wherein:

FIG. 1 is a schematic representation of a combined multicomponent refrigerant cycle used with an air separation unit, as known in the art.

FIG. 2 is another schematic representation of a combined multicomponent refrigerant cycle used with an air separation unit, as known in the art.

FIG. 3 is a schematic representation of the heat flow within the main heat exchanger in a system configured as described in FIG. 2.

FIG. 4 is a schematic representation of a combined multicomponent refrigerant cycle used with an air separation unit, in accordance with one embodiment of the present invention.

FIG. 5 is a schematic representation of the heat flow within the main heat exchanger in a system configured as described in FIG. 4.

FIG. 6 is a schematic representation of a combined multicomponent refrigerant cycle used with an air separation unit, in accordance with one embodiment of the present invention.

ELEMENT NUMBERS

• • 101=purified feed air stream
  • 102=main heat exchanger
  • 103=higher-pressure column
  • 104=nitrogen enriched vapor stream
  • 105=main condenser
  • 106=nitrogen-enriched liquid stream
  • 107=sub-cooler
  • 108=lower-pressure column
  • 109=product liquid nitrogen stream
  • 110=oxygen enriched liquid stream
  • 111=sub-cooler
  • 112=first portion (of oxygen-enriched liquid)
  • 113=second portion (of oxygen-enriched liquid)
  • 114=argon column condenser
  • 115=nitrogen rich vapor stream
  • 116=waste stream
  • 117=nitrogen enriched liquid (to sub-cooler)
  • 118=oxygen rich vapor stream
  • 119=product gaseous oxygen stream
  • 120=liquid oxygen
  • 121=oxygen and argon containing stream
  • 122=argon column
  • 123=oxygen-richer fluid (from argon column)
  • 124=product liquid argon
  • 125=low-pressure multicomponent refrigerant stream
  • 126=multicomponent refrigerant recycle compressor
  • 127=multicomponent refrigerant aftercooler
  • 128=compressed multicomponent refrigerant stream
  • 129=cooled, compressed multicomponent refrigerant stream
  • 130=multicomponent refrigerant stream throttle valve
  • 131=refrigeration bearing multicomponent refrigerant stream
  • 201=warm multicomponent refrigerant return steam
  • 202=multicomponent refrigerant compressor
  • 203=pressurized multicomponent refrigerant stream
  • 204=multicomponent refrigerant cooler
  • 205=cooled pressurized multicomponent refrigerant stream
  • 206=first phase separator vessel
  • 207=first vapor portion (from first phase separator)
  • 208=first liquid portion (from first phase separator)
  • 209=liquefaction heat exchanger
  • 210=first nitrogen recycle stream
  • 211=low-pressure nitrogen compressor
  • 212=warm medium-pressure nitrogen stream
  • 213=first nitrogen cooler
  • 214=cooled medium-pressure nitrogen stream
  • 215=air separation unit
  • 216=second nitrogen recycle stream
  • 217=combined medium-pressure nitrogen stream
  • 218=medium-pressure nitrogen compressor
  • 219=warm intermediate-pressure nitrogen stream
  • 220=second nitrogen cooler
  • 221=cooled intermediate-pressure nitrogen stream
  • 222=high-pressure nitrogen booster
  • 223=high-pressure nitrogen stream
  • 224=first nitrogen refrigeration stream
  • 225=second nitrogen refrigeration stream
  • 226=nitrogen expander
  • 227=expanded nitrogen stream
  • 228=fifth phase separator vessel
  • 229=nitrogen vapor portion (from fifth phase separator)
  • 230=nitrogen liquid portion (from fifth phase separator)
  • 231=combined nitrogen stream
  • 232=internal liquid nitrogen stream
  • 233=return portion (of internal liquid nitrogen stream)
  • 234=storage portion (of internal liquid nitrogen stream)
  • 235=cold nitrogen recycle stream
  • 236=inlet natural gas stream
  • 237=liquid natural gas stream
  • 238=compressed and purified inlet air stream
  • 239=first heat exchanger
  • 240=medium-pressure nitrogen stream
  • 241=liquid oxygen stream
  • 242=warmed first vapor stream
  • 243=second phase separator vessel
  • 244=second vapor portion (from second phase separator)
  • 245=second liquid portion (from second phase separator)
  • 246=at least partially condensed portion
  • 247=warm second liquid portion
  • 248=warmed first liquid stream
  • 249=third phase separator vessel
  • 250=third vapor portion (from third phase separator)
  • 251=third liquid portion (from third phase separator)
  • 252=third combined multicomponent refrigerant stream
  • 253=warm combined nitrogen steam
  • 254=fourth phase separator vessel
  • 255=fourth vapor portion (from fourth phase separator)
  • 256=fourth liquid portion (from fourth phase separator)
  • 257=fourth combined multicomponent refrigerant stream
  • 301=warm multicomponent refrigerant return steam
  • 302=combined multicomponent return stream
  • 303=multicomponent refrigerant compressor
  • 304=pressurized multicomponent refrigerant stream
  • 305=first part (of pressurized multicomponent refrigerant stream)
  • 306=multicomponent refrigerant cooler
  • 307=cooled multicomponent refrigerant stream
  • 308=first phase separator vessel
  • 309=first vapor portion (from first phase separator)
  • 310=first liquid portion (from first phase separator)
  • 311=warmed first vapor stream
  • 312=second phase separator vessel
  • 313=second vapor portion (from second phase separator)
  • 314=second liquid portion (from second phase separator)
  • 315=second combined multicomponent refrigerant stream
  • 316=warm combined nitrogen steam
  • 317=warmed first liquid stream
  • 318=third phase separator vessel
  • 319=third vapor portion (from third phase separator)
  • 320=third liquid portion (from third phase separator)
  • 321=third combined multicomponent refrigerant stream
  • 322=inlet air stream
  • 323=main air compressor
  • 324=inlet air cooler
  • 325a/b=air purification vessel
  • 326=purified inlet air stream
  • 327=Claude compressor
  • 328=boosted air cooler
  • 329=cooled, boosted air stream
  • 330=cold air stream
  • 331=condensed first portion (of cooled inlet air)
  • 332=second portion (of cooled inlet air)
  • 333=Claude expander
  • 334=expanded second portion
  • 335=distillation column
  • 336=liquid nitrogen product
  • 337=liquid oxygen product stream
  • 338=liquid oxygen stream
  • 339=liquid oxygen pump
  • 340=high-pressure liquid oxygen stream
  • 341=high-pressure gaseous oxygen product stream
  • 342=waste nitrogen stream
  • 343=warmed waste nitrogen stream
  • 344=waste nitrogen heater
  • 345=hot waste nitrogen stream
  • 346ab=regeneration waste stream
  • 347=first liquefaction heat exchanger
  • 348=multicomponent refrigerant cycle
  • 349=first part (of pressurized multicomponent refrigerant stream)
  • 350=warm multicomponent refrigerant return steam
  • 351=supplemental compressor
  • 352=cold inlet stream
  • 402=multicomponent refrigerant cooler
  • 403=cooled pressurized multicomponent refrigerant stream
  • 404=first phase separator vessel
  • 405=first vapor portion (from first phase separator)
  • 406=first liquid portion (from first phase separator)
  • 407=second liquefaction heat exchanger
  • 408=inlet natural gas stream
  • 409=cool natural gas stream
  • 410=fifth phase separator vessel
  • 411=fifth vapor portion (from fifth phase separator)
  • 412=fifth liquid portion (from fifth phase separator)
  • 413=liquid natural gas stream
  • 414=warmed first vapor stream
  • 415=second phase separator vessel
  • 416=second vapor portion (from second phase separator)
  • 417=second liquid portion (from second phase separator)
  • 418=at least partially condensed portion
  • 419=warm second liquid portion
  • 420=warmed first liquid stream
  • 421=third phase separator vessel
  • 422=third vapor portion (from third phase separator)
  • 423=third liquid portion (from third phase separator)
  • 424=third combined multicomponent refrigerant stream
  • 425=warm combined nitrogen steam
  • 426=fourth phase separator vessel
  • 427=fourth vapor portion (from fourth phase separator)
  • 428=fourth liquid portion (from fourth phase separator)
  • 429=fourth combined multicomponent refrigerant stream

DESCRIPTION OF PREFERRED EMBODIMENTS

Illustrative embodiments of the invention are described below. While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and are herein described in detail. It should be understood, however, that the description herein of specific embodiments is not intended to limit the invention to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.

It will of course be appreciated that in the development of any such actual embodiment, numerous implementation-specific decisions must be made to achieve the developer's specific goals, such as compliance with system-related and business-related constraints, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming, but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure.

FIG. 4 and FIG. 6 illustrate two separate parts of a single integrated system. FIG. 4 illustrates an ASU system with an integrated multicomponent refrigerant cycle. FIG. 6 illustrates a natural gas liquefaction system with an integrated multicomponent refrigerant cycle. Both multicomponent refrigerant cycles share a common mixed refrigerant compressor (multicomponent refrigerant compressor 303).

Turning now to FIG. 4, the multicomponent refrigerant cycle 348 includes warm multicomponent refrigerant return steam 301, which is at reduced pressure. Warm multicomponent refrigerant return stream 301 is combined with warm multicomponent refrigerant return steam 350 (described below) and combined multicomponent return stream 302 has the pressure increased in multicomponent refrigerant compressor 303, thereby producing pressurized multicomponent refrigerant stream 304. Pressurized multicomponent refrigerant stream 304 is split into a first part 349 and a second part 305. First part 349 is sent to second liquefaction heat exchanger 407 (described below). Second part 305 enters multicomponent refrigerant cooler 306, thereby producing cooled multicomponent refrigerant stream 307. Cooled multicomponent refrigerant stream 307 is introduced into first phase separator vessel 308, which produces first vapor portion 309 and first liquid portion 310.

After passing through first liquefaction heat exchanger 347, first vapor portion 309 exits as warmed first vapor stream 311. Warmed first vapor stream 311 is introduced to second phase separator vessel 312, which produces second vapor portion 313 and second liquid portion 314. Second vapor portion 313 and second liquid portion 314 are combined to form second combined multicomponent refrigerant stream 315, which is introduced into first liquefaction heat exchanger 347. After passing through first liquefaction heat exchanger 347 second combined multicomponent refrigerant stream 315 exits as warmed combined nitrogen stream 316.

After passing through first liquefaction heat exchanger 347, first liquid portion 310 exits as warmed first liquid stream 317. Warmed first liquid stream 317 and warmed combined nitrogen stream 316 are introduced into third phase separator vessel 318. Third phase separator vessel 318 produces third vapor portion 319 and third liquid portion 320. Third vapor portion 319 and third liquid portion 320 are combined to form third combined multicomponent refrigerant stream 321, which is introduced into first liquefaction heat exchanger 347. After passing through first liquefaction heat exchanger 347, third combined multicomponent refrigerant stream 321 exits as warm multicomponent refrigerant return steam 301.

Multicomponent refrigerant cycle and nitrogen refrigeration cycle work together to provide sufficient refrigeration duty to liquefy inlet natural gas stream 408 into liquid natural gas stream 413 (described below).

Inlet air stream 322 enters main air compressor 323 wherein the pressure is increased, and the pressurized air is cooled in inlet air cooler 324. The cooled, compressed air stream is then directed to one of air purification vessel 325a/b, wherein the inlet air stream is purified, thereby producing purified inlet air stream 326. Purified inlet air stream 326 is then compressed in Claude compressor 327 and cooled in boosted air cooler 328. Cooled, boosted air stream 329 then enters first liquefaction heat exchanger 347, thereby forming cold air stream 330. After having the temperature reduced, first portion 331 of cold air stream 330 exits first liquefaction heat exchanger 347, is optionally further compressed in supplemental compressor 351, and then enters distillation column 335 as cold inlet stream 352.

Second portion 332 of the cold air stream 330 exits first liquefaction heat exchanger 347 and then enters Claude expander 333. Expanded second air stream 334 then enters distillation column 335. Distillation column 335 produces at least liquid nitrogen product stream 336, waste nitrogen stream 342, optional liquid oxygen stream 338, and liquid oxygen product stream 337. In order to produce the desired flowrate in both optional liquid oxygen stream 338 and liquid oxygen product stream 337, it is necessary to introduce additional refrigeration duty, in the form of expanded second air stream 334. At least a portion of the liquid oxygen from distillation column 335 may be exported as a liquid oxygen product stream 337.

Optionally, liquid oxygen stream 338 may be removed from distillation column 335. Liquid oxygen stream 338 is increased in pressure in liquid oxygen pump 339, thereby producing high-pressure liquid oxygen stream 340. High-pressure liquid oxygen stream 340 is then introduced into first liquefaction heat exchanger 347, wherein it is heated and vaporized, thereby producing optional high-pressure gaseous oxygen product stream 341, which then exits the system. One skilled in the art will recognize that liquid oxygen pump 339 may just as easily product low-pressure or medium-pressure liquid oxygen, and therefore the system may produce low-pressure or medium-pressure gaseous oxygen (not shown) in addition to the high-pressure gaseous oxygen system as illustrated. All oxygen product streams may be only liquid. Or a portion may be liquid and additional (optional) portions maybe low-pressure gaseous oxygen and/or high-pressure gaseous oxygen.

After passing through first liquefaction heat exchanger 347, warmed waste nitrogen stream 343 is heated in waste nitrogen heater 344, thereby producing hot waste nitrogen stream 345. Hot waste nitrogen stream 345 is then used to regenerate air purification vessels 325a/b as needed, with the resulting regeneration waste exiting in regeneration waste streams 346a/b. FIG. 5 illustrates the heat flow within the main heat exchanger in a system configured as described in FIG. 4.

Turning now to FIG. 6, the multicomponent refrigerant cycle includes warm multicomponent refrigerant return steam 350, which is at reduced pressure. As described above, warm multicomponent refrigerant return stream 350 is combined with warm multicomponent refrigerant return stream 301 and combined multicomponent return stream 302 has the pressure increased in multicomponent refrigerant compressor 303, thereby producing pressurized multicomponent refrigerant stream 304. Pressurized multicomponent refrigerant stream 304 is split into a first part 349 and a second part 305. First part 349 enters multicomponent refrigerant cooler 402, thereby producing cooled pressurized multicomponent refrigerant stream 403. Cooled, pressurized multicomponent refrigerant stream 403 is introduced to first phase separator vessel 404, which produces first vapor portion 405 and first liquid portion 406.

After passing through second liquefaction heat exchanger 407, first vapor portion 405 exits as warmed first vapor stream 414. Warmed first vapor stream 414 is introduced to second phase separator vessel 415, which produces second vapor portion 416 and second liquid portion 417. Second vapor portion 416 is introduced into second liquefaction heat exchanger 407. After passing through second liquefaction heat exchanger 407 second vapor portion 416 exits as cooled to form at least partially condensed portion 418. Second liquid portion 417 is introduced into second liquefaction heat exchanger 407. After passing through second liquefaction heat exchanger 407, second liquid portion 417 exits as warm second liquid portion 419.

After passing through second liquefaction heat exchanger 407, first liquid portion 406 exits as warmed first liquid stream 420. At least partially condensed portion 418 is introduced into third phase separator vessel 421. Third phase separator vessel 421 produces third vapor portion 422 and third liquid portion 423. Third vapor portion 422 and third liquid portion 423 are combined to form third combined multicomponent refrigerant stream 424, which is introduced into second liquefaction heat exchanger 407. After passing through second liquefaction heat exchanger 407, third combined multicomponent refrigerant stream 424 exits as warm combined multicomponent refrigerant steam 425.

Warmed second liquid portion 419, warmed first liquid stream 420, and warm combined multicomponent refrigerant steam 425 are introduced to fourth phase separator vessel 426. Exiting fourth phase separator vessel 426 are fourth vapor portion 427 and fourth liquid portion 428. Fourth vapor portion 427 and fourth liquid portion 428 are combined to form fourth combined multicomponent refrigerant stream 429, which is introduced into second liquefaction heat exchanger 407. After passing through second liquefaction heat exchanger 407, fourth combined multicomponent refrigerant stream 429 exits as warm multicomponent refrigerant return steam 350.

Inlet natural gas stream 408 is introduced into liquefaction heat exchanger 407 and exits as cool natural gas stream 409. Cool natural gas stream 409 is introduced to fifth phase separator vessel 410, which produces fifth vapor portion 411 and fifth liquid portion 412. Fifth vapor portion 411 reenters liquefaction heat exchanger 407 and exits as liquid natural gas stream 413.

It is understood, but not shown in FIG. 6, that there will be pressure reducing valves on streams 419, 420, and 418

Multicomponent refrigerant cycle and nitrogen refrigeration cycle work together to provide sufficient refrigeration duty to liquefy inlet natural gas stream 408 into liquid natural gas stream 413.

One skilled in the art will recognize a number of advantages of the proposed common MR compression system 348 with independent heat exchange systems for a) NG liquefaction 407 and b) ASU refrigeration 347.

• • 1) Significant compression equipment cost savings as compared to individual ASU and NG compression and liquefaction systems.
  • 2) The NG liquefaction system design may now be standardized and/or copied from typical known stand-alone NG liquefaction systems but with the savings (removal of) the MR compression since the compression is now common.
  • 3) Oxygen rich streams are common in ASU exchangers, and it is desirable to keep flammable components away from oxygen rich streams. With the proposed arrangement, the flammable NG product is removed from the ASU exchanger. The common MR components may be selected from a list of nonflammable components such as environmentally acceptable fluorocarbons.

It will be understood that many additional changes in the details, materials, steps and arrangement of parts, which have been herein described in order to explain the nature of the invention, may be made by those skilled in the art within the principle and scope of the invention as expressed in the appended claims. Thus, the present invention is not intended to be limited to the specific embodiments in the examples given above.

Claims

1. A hybrid process of air separation and gas liquefaction, comprising: wherein the first multicomponent refrigerant return stream and the second multicomponent refrigerant return are recompressed in a common compression system, thereby producing the compressed multicomponent refrigerant stream.

dividing a compressed multicomponent refrigerant stream into a first portion and a second portion,

introducing the first portion into a gas liquefaction system, thereby producing a first multicomponent refrigerant return stream, and

introducing the second portion into an air separation system, thereby producing a second multicomponent refrigerant return stream.

2. The hybrid process of claim 1, wherein the multicomponent refrigerant stream comprises one or more of the following components: nitrogen, argon, methane, ethane ethylene, propane, butane, pentane, and fluorocarbons.

3. The hybrid process of claim 1, wherein a gaseous natural gas stream enters the gas liquefaction system and a liquid natural gas stream exits the gas liquefaction system.

4. The hybrid process of claim 1, wherein the air separation system produces at least one liquid oxygen stream.

5. The hybrid process of claim 1, wherein the compression system is a single compressor.

6. The hybrid process of claim 1, wherein the compression system comprises at least two or more parallel compressors.