# Patent

## Title
Method for producing a flow rich in methane and a flow rich in C2 +  hydrocarbons, and associated installation

## Abstract

This method comprises cooling the supply flow in a first heat exchanger, separation in a first separation flask in order to produce a light upper flow and a heavy lower flow and dividing the light upper flow into a supply fraction of a dynamic pressure reduction turbine and a supply fraction of a first distillation column.
The method comprises forming a cooled reflux flow from an effluent from a dynamic pressure reduction turbine, the portion of the effluent being cooled and at least partially liquefied in a heat exchanger.
It comprises introducing the cooled reflux flow from the heat exchanger into the first distillation column.

## Background
BACKGROUND OF THE INVENTION
The present invention relates to a method for producing a flow rich in methane and a flow rich in C2+ hydrocarbons from a supply flow containing hydrocarbons, of the type comprising the following steps:

    
    
        cooling at least a first fraction of the supply flow in a first heat exchanger;
        introducing the first cooled supply fraction into a first separation flask in order to produce a light upper flow and a heavy lower flow;
        dividing the light upper flow into a turbine supply fraction and a column supply fraction;
        pressure reduction of the turbine supply fraction in a first dynamic pressure reduction turbine and introduction of at least a portion of the fraction subjected to pressure reduction into the first turbine in a middle portion of a first distillation column;
        cooling and at least partially condensing the column supply fraction in a second heat exchanger, pressure reduction and introduction of the cooled column supply fraction into an upper portion of the first distillation column;
        pressure reduction and partial vaporisation of the heavy lower flow in the first heat exchanger and introduction of the heavy lower flow subjected to pressure reduction into a second separation flask in order to produce an upper gas fraction and a lower liquid fraction;
        pressure reduction of the lower liquid fraction and introduction in the middle portion of the first distillation column;
        cooling and at least partially condensing of the upper gas fraction in the second heat exchanger and introduction into the upper portion of the first distillation column;
        recovery of a lower column flow at the bottom of the first distillation column, the flow rich in C2+ hydrocarbons being formed from the lower column flow;
        recovery and reheating of an upper column flow rich in methane,
        compressing at least a fraction of the upper column flow in at least a first compressor coupled to the first dynamic pressure reduction turbine and in at least a second compressor;
        forming the flow rich in methane from the reheated and compressed upper column flow;
        removing an extraction flow from the upper column flow;
        cooling and introducing the cooled extraction flow into an upper portion of the first distillation column.
    
    


Such a method is intended to extract C2+ hydrocarbons, such as in particular ethylene, ethane, propylene, propane and heavier hydrocarbons, particularly from natural gas, refinery gas or synthetic gas obtained from other hydrocarbon sources, such as carbon, crude oil, naphtha.
Natural gas generally contains a majority of methane and ethane constituting at least 50 mol % of the gas. It also contains, in a more negligible quantity, heavier hydrocarbons, such as propane, butane, pentane. In some cases, it also contains helium, hydrogen, nitrogen and carbon dioxide.
It is necessary to separate the heavy hydrocarbons from the natural gas in order to comply with at least two imperatives.
Firstly, economically, C2+ hydrocarbons and particularly ethane, propane and butane have a worth which can be exploited. Furthermore, the demand for liquid natural gas as a charge for the petrochemical industry increases continuously and should continue to increase in the years ahead.
Furthermore, for processing reasons, it is desirable to separate the heavy hydrocarbons in order to prevent them from condensing during transport and/or handling of the gases.
This allows prevention of incidents such as the occurrence of liquid plugs in transport or processing installations configured for gaseous effluents.
In order to separate the C2+ hydrocarbons from the natural gas, it is known to use an oil absorption method which allows recovery of up to 90% of the propane and up to approximately 40% of the ethane.
In order to achieve higher recovery rates, cryogenic expansion methods are used.
In a known cryogenic expansion method, a portion of the supply flow containing the hydrocarbons is used for the secondary distillers of a methane separation column.
Subsequently, the various effluents, after partial condensation, are combined in order to supply a gas/liquid separator.
As described in U.S. Pat. No. 5,555,748, the light flow obtained in the upper portion of the separator is divided into a first column supply fraction, which is condensed before being conveyed to the upper supply of the distillation column and a second fraction which is conveyed to a dynamic pressure reduction turbine before being reintroduced into the distillation column.
This method has the advantage of being easy to start and of providing substantial operating flexibility, combined with good efficiency and good reliability.
However, economic constraints require a further increase in the efficiency of the method whilst retaining a very high level of efficiency of ethane extraction. It is further necessary to minimise the spatial requirement of the installations and to reduce, or even dispense with, the provision of external coolants such as propane, in particular for carrying out the method on floating installations or in zones which are sensitive in terms of security.
SUMMARY OF THE INVENTION
Therefore, an object of the invention is to obtain a production method which allows separation of a supply flow containing hydrocarbons into a flow rich in C2+ hydrocarbons and a flow rich in methane, in a very economical and very efficient manner, taking up little space.
To that end, the invention relates to a method of the above-mentioned type, characterised in that the method comprises the following steps:

    
    
        forming a cooled reflux flow from at least a portion of an effluent from a dynamic pressure reduction turbine, the portion of the effluent from the dynamic pressure reduction turbine being cooled and at least partially liquefied in a heat exchanger in order to form the cooled reflux flow.
    
    


The method according to the invention may comprise one or more of the following features, taken in isolation or in accordance with any technically possible combination:

    
    
        it comprises the following steps:
        removing a reboiling flow from the first distillation column at a removal level;
        placing the reboiling flow in a heat exchange relationship with the portion of the effluent from a dynamic pressure reduction turbine in the heat exchanger in order to cool and at least partially liquefy the portion of the effluent from the dynamic pressure reduction turbine, and
        reintroducing the reboiling flow into the first distillation column at a level lower than the removal level;
        the effluent of the dynamic pressure reduction turbine is formed by the fraction subjected to pressure reduction from the first dynamic pressure reduction turbine, the method comprising the introduction of the fraction subjected to pressure reduction from the first dynamic pressure reduction turbine into the second heat exchanger in order to be cooled and partially liquefied therein;
        it comprises the following steps:
        separating the supply flow into a first fraction of the supply flow and at least a second fraction of the supply flow,
        introducing the first fraction of the supply flow into the first heat exchanger;
        introducing at least a portion of the second fraction of the supply flow into a second dynamic pressure reduction turbine, separate from the first dynamic pressure reduction turbine, the fraction subjected to pressure reduction from the second dynamic turbine forming the effluent from the dynamic pressure reduction turbine;
        it comprises the following steps:
        introducing the fraction subjected to pressure reduction from the second dynamic pressure reduction turbine into a downstream separation flask in order to form a third upper gas flow and a third lower liquid flow;
        cooling the third upper gas flow in the heat exchanger in order to form the cooled reflux flow;
        the third upper gas flow is introduced, after cooling, into an auxiliary distillation column, the cooled reflux flow being formed from the lower flow of the auxiliary distillation column;
        it comprises the following steps:
        cooling and partially condensing the second supply flow fraction;
        introducing the second cooled supply flow fraction into an upstream separation flask in order to form a second gas fraction and a second liquid fraction;
        introducing the second gas fraction into the second dynamic pressure reduction turbine;
        introducing the second liquid fraction, after pressure reduction, into a lower portion of the first distillation column;
        the whole of the second fraction of the supply flow is introduced into the second dynamic pressure reduction turbine without cooling between the step of separating the supply flow and the step of introducing the second fraction of the supply flow into the second dynamic pressure reduction turbine;
        it comprises the following steps:
        removing a secondary compression fraction from the upper column flow rich in methane, before the upper column flow rich in methane is passed into the first compressor,
        passing the secondary compression fraction into a third compressor coupled to the second dynamic pressure reduction turbine;
        introducing the compressed secondary compression fraction from the third compressor into the compressed upper column flow, downstream of the first compressor;
        it comprises the following steps:
        removing a make-up cooling flow from the upper column flow rich in methane or from a flow formed from the upper column flow rich in methane;
        pressure reduction and introduction of the make-up cooling flow subjected to pressure reduction into a flow flowing upstream of the first pressure reduction turbine, advantageously into the first fraction of the cooled supply flow or the turbine supply fraction;
        it comprises the following steps:
        passing the upper column flow rich in methane into the first heat exchanger;
        removing an auxiliary pressure reduction flow from the upper column flow rich in methane, after it has been passed into the first heat exchanger;
        dynamic pressure reduction of the auxiliary pressure reduction flow in an auxiliary dynamic pressure reduction turbine;
        introducing the flow subjected to pressure reduction from the auxiliary dynamic pressure reduction turbine into the upper column flow rich in methane before it is passed into the first heat exchanger;
        the second compressor comprises a first compression stage, at least a second compression stage and a cooler interposed between the first compression stage and the second compression stage, the method comprising a step of passing the compressed upper column flow from the first compressor successively into the first compression stage, into the cooler, then into the second compression stage;
        the portion of the effluent from the dynamic pressure reduction turbine, the upper column flow, the column supply fraction and the upper gas fraction are placed in a heat exchange relationship in the second heat exchanger; and
        at least a fraction of the upper column flow and the portion of the effluent of the dynamic pressure reduction turbine are placed in a heat exchange relationship in a downstream heat exchanger separate from the second heat exchanger;
        the auxiliary reboiling flow is placed in a heat exchange relationship with the flow from the dynamic pressure reduction turbine in the second heat exchanger;
        no external cooling cycle is used to cool the first fraction of the supply flow in the first heat exchanger;
        the lower column flow is pumped and is advantageously reheated by being placed in a heat exchange relationship with at least a fraction of the supply flow up to a temperature less than its bubble temperature.
    
    


The invention further relates to an installation for producing a flow rich in methane and a flow rich in C2+ hydrocarbons from a supply flow containing hydrocarbons, of the type comprising:

    
    
        a first heat exchanger for cooling at least a first fraction of the supply flow;
        a first separation flask and means for introducing the first cooled supply fraction into the first separation flask in order to produce a light upper flow and a heavy lower flow;
        means for dividing the light upper flow into a turbine supply fraction and a column supply fraction;
        a first distillation column;
        pressure reduction means for the turbine supply fraction comprising a first dynamic pressure reduction turbine and means for introducing at least a portion of the fraction subjected to pressure reduction into the first turbine in a middle portion of the first distillation column;
        means for cooling and at least partially condensing the column supply fraction comprising a second heat exchanger and means for pressure reduction and introduction of the cooled column supply fraction into an upper portion of the first distillation column;
        means for pressure reduction and means for partial vaporisation of the heavy lower flow comprising the first heat exchanger;
        a second separation flask and means for introducing the heavy lower flow into the second separation flask in order to produce an upper gas fraction and a lower liquid fraction;
        means for pressure reduction of the lower liquid fraction and means for introduction into the middle portion of the first distillation column;
        means for cooling and at least partially condensing the upper gas fraction comprising the second heat exchanger and means for introducing the upper gas fraction into the upper portion of the first distillation column;
        means for recovering a lower column flow at the bottom of the first distillation column, and means for forming the flow rich in C2+ hydrocarbons from the lower column flow;
        means for recovering and reheating an upper column flow rich in methane, at the top of the first distillation column;
        means for compressing at least a fraction of the upper column flow comprising at least a first compressor coupled to the first dynamic pressure reduction turbine and at least a second compressor;
        means for forming the flow rich in methane from the reheated and compressed upper column flow;
        means for removing from the upper column flow an extraction flow,
        means for cooling and introducing the cooled extraction flow into an upper portion of the first distillation column; characterised in that the installation comprises:
        means for forming a cooled reflux flow from at least a portion of an effluent from a dynamic pressure reduction turbine, the portion of the effluent from the dynamic pressure reduction turbine being cooled and at least partially liquefied in a heat exchanger in order to form the cooled reflux flow,
        means for introducing the cooled reflux flow from the heat exchanger into the first distillation column.
    
    


The invention will be better understood from a reading of the following description, which is given purely by way of example and with reference to the appended drawings, in which:



BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a functional schematic illustration of a first production installation intended for carrying out a first method according to the invention;
FIG. 2 is a functional schematic illustration of a second production installation intended for carrying out a second method according to the invention;
FIG. 3 is a functional schematic illustration of a third production installation intended for carrying out a third method according to the invention;
FIG. 4 is a functional schematic illustration of a fourth production installation intended for carrying out a fourth method according to the invention;
FIG. 5 is a functional schematic illustration of a fifth production installation intended for carrying out a fifth method according to the invention;
FIG. 6 is a functional schematic illustration of a sixth production installation intended for carrying out a sixth method according to the invention;
FIG. 7 is a functional schematic illustration of a seventh production installation intended for carrying out a seventh method according to the invention;
FIG. 8 is a functional schematic illustration of an eighth production installation intended for carrying out an eighth method according to the invention.



DESCRIPTION OF PREFERRED EMBODIMENTS
Hereinafter, a flow flowing in a conduit and the conduit which transports it will be referred to using the same reference numerals.
Furthermore, unless otherwise indicated, the percentages set out are molar percentages and the pressures are given in bar absolute. The efficiency level of each compressor is selected to be 82% polytropic and the efficiency level of each turbine is 85% adiabatic. Similarly, the distillation columns described use plates but they can also use loose or structured lining. A combination of plates and lining is also possible. The additional turbines described drive compressors but they can also drive electrical generators having variable frequency whose electricity produced may be used in the network by means of a frequency converter. The flows whose temperature is above ambient are described as being cooled by air coolers. In a variant, it is possible to use water exchangers, for example, with fresh water or sea water.
FIG. 1 illustrates a first installation 10 for producing a flow 12 rich in methane and a cut 14 rich in C2+ hydrocarbons according to the invention, from a supply gas flow 16.
The gas flow 16 is a flow of natural gas, a flow of refinery gas or a flow of synthetic gas obtained from a hydrocarbon source such as carbon, crude oil, naphtha. In the example illustrated in the Figures, the flow 16 is a flow of dehydrated natural gas.
The method and the installation 10 are advantageously used in the construction of a new unit for the recovery of methane and ethane.
The installation 10 comprises, in a downstream direction, a first heat exchanger 20, a first separation flask 22, a second separation flask 24 and a first dynamic pressure reduction turbine 26, capable of producing work during the pressure reduction of a flow passing through the turbine.
The installation further comprises a second heat exchanger 28, a first distillation column 30, a first compressor 32 coupled to the first dynamic pressure reduction turbine 26, a first cooler 34, a second compressor 36, a second cooler 38 and a column bottom pump 40.
A first production method according to the invention, carried out in the installation 10, will now be described.
The supply flow 16 of a dehydrated natural gas comprises, in moles, 2.06% of nitrogen, 83.97% of methane, 6.31% of ethane, 3.66% of propane, 0.70% of isobutane, 1.50% of n-butane, 0.45 of isopentane, 0.83% of n-pentane and 0.51% of carbon dioxide.
Therefore, the supply flow 16 more generally has, in moles, between 5% and 15% of C2+ hydrocarbons to be extracted and between 75% and 90% of methane.
The term “dehydrated gas” is intended to refer to a gas whose water content is as low as possible and is particularly less than 1 ppm.
The supply flow 16 has a pressure greater than 35 bar and a temperature similar to the ambient temperature and particularly substantially of 30° C. The flow rate of the supply flow is in this example 15,000 kmol/hour.
In the example illustrated, the supply flow 16 is introduced in its entirety into the first heat exchanger 20, where it is cooled and partially condensed in order to form a fraction 42 of cooled supply flow.
The temperature of the fraction 42 is less than −10° C. and is particularly of −26° C. Subsequently, the cooled fraction 42 is introduced into the first separation flask 22.
The liquid content of the cooled fraction 42 is less than 50 mol %.
A light upper gas flow 44 and a heavy lower liquid flow 45 are extracted from the first separation flask 22. The gas flow 44 is divided into a minority column supply fraction 46 and a majority turbine supply fraction 48. The ratio of the molar flow of the majority fraction 48 to the minority fraction 46 is greater than 2.
The column supply fraction 46 is introduced into the second exchanger 28 in order to be completely liquefied and sub-cooled therein. It forms a cooled column supply fraction 49. That fraction 49 is subjected to pressure reduction in a first static pressure reduction valve 50 in order to form a fraction 52 subjected to pressure reduction that is introduced by reflux into the first distillation column 30.
The temperature of the fraction 52 subjected to pressure reduction obtained after being passed through the valve 50 is less than −70° C. and is particularly of −109° C.
The pressure of the fraction 52 subjected to pressure reduction is further substantially equal to the operating pressure of the column 30 which is less than 40 bar and in particular between 10 bar and 30 bar, advantageously of 20 bar.
The fraction 52 is introduced into an upper portion of the column 30 at a level N1 located, for example, at the fifth stage from the top of the column 30.
The turbine supply fraction 48 is introduced into the first dynamic pressure reduction turbine 26. It is subjected to dynamic expansion as far as a pressure in the region of the operating pressure of the column 30 in order to form a supply fraction 54 subjected to pressure reduction which has a temperature of less than −50° C.
According to the invention, the fraction 54 subjected to pressure reduction is conveyed into the second heat exchanger 28 in order to be cooled therein and to form an additional cooled reflux flow 56.
The expansion of the supply fraction 48 in the first turbine 26 allows recovery of 4584 kW of energy which cools the fraction 48.
According to the invention, the flow 54, which is an effluent from a dynamic pressure reduction turbine 26 is cooled and is at least partially liquefied to constitute a first cooled reflux flow 56.
The temperature of the cooled reflux flow 56 is less than −60° C.
The liquid content of the cooled reflux flow 56 is greater than 5 mol %.
The cooled reflux flow 56 is introduced into a middle portion of the column 30 located below the upper portion, at a level N2 corresponding to the tenth stage from the top of the column 30.
The liquid flow 45 recovered at the bottom of the first separation flask 22 is subjected to pressure reduction in a second static pressure reduction valve 58, then is reheated in the first heat exchanger 20 and is partially vaporised in order to form a heavy flow 60 subjected to pressure reduction.
The pressure of the heavy flow 60 subjected to pressure reduction is less than 50 bar and is particularly substantially of 20.7 bar. The temperature of the heavy flow 60 subjected to pressure reduction is greater than −50° C. and is particularly substantially of −20° C.
The heavy flow 60 subjected to pressure reduction is subsequently introduced into the second separation flask 24 in order to be separated therein into an upper gas fraction 62 and a lower liquid fraction 64.
The lower liquid fraction 64 is subjected to pressure reduction substantially to the operating pressure of the column 30 through a third static pressure reduction valve 66.
The liquid fraction 68 subjected to pressure reduction from the third valve 66 is introduced by reflux into a middle portion of the first column 30, at a level N3 located below the level N2, advantageously at the fourteenth stage from the top of the first column 30.
The upper gas fraction 62 is introduced into the second heat exchanger 28 in order to be cooled and completely liquefied therein. It is subsequently subjected to pressure reduction in a fourth static pressure reduction valve 70 and forms a fraction 72 subjected to pressure reduction. The temperature of the fraction 72 subjected to pressure reduction is less than −70° C. and is particularly of −106.9° C. Its pressure is substantially equal to the pressure of the column 30.
The fraction 72 subjected to pressure reduction is introduced by reflux into an upper portion of the column 30 located at a level N5 positioned between the level N1 and the level N2, advantageously at the fifth stage from the top of the column 30. The temperature of the liquid fraction 68 subjected to pressure reduction is less than 0° C. and is particularly of −20.4° C.
A first reboiling flow 74 is removed in the region of the bottom of the column 30 at a temperature greater than −3° C. and particularly substantially of 12.08° C., at a level N6 advantageously located at the twenty-first stage from the top of the column 30.
The first flow 74 is brought to the first heat exchanger 20 where it is reheated up to a temperature greater than 3° C. and in particular of 18.88° C. before being conveyed to a level N7 corresponding to the twenty-second stage from the top of the column 30.
A second reboiling flow 76 is removed at a level N8 located above the level N6 and below the level N3, advantageously at the eighteenth stage from the top of the column. The second reboiling flow 76 is introduced into the first heat exchanger 20 in order to be reheated therein to a temperature greater than −8° C. and in particular of 7.23° C. It is subsequently conveyed into the column 30 at a level N9 located below the level N8 and above the level N6, advantageously at the nineteenth stage from the top of the column 30.
A third reboiling flow 78 is removed at a level N10 located below the level N3 and above the level N8, advantageously at the fifteenth stage from the top of the column 30. The third reboiling flow 78 is subsequently conveyed to the first heat exchanger 20 where it is reheated to a temperature greater than −30° C. and particularly of −15.6° C. before being conveyed to a level N11 of the column 30 located below the level N10 and above the level N8, advantageously at the sixteenth stage from the top of the column 30.
According to the invention, a fourth reboiling flow 80 is removed from a middle portion of the column 30 at a level N12 located below the level N2 and above the level N3, and advantageously at the twelfth stage from the top of the column 30.
That fourth reboiling flow 80 is conveyed to the second heat exchanger 28 where it is reheated by heat exchange with the effluent 54 from the turbine 26 up to a temperature greater than −50° C. It thereby exchanges thermal power which allows provision of a portion of the kilogram calories necessary for the formation of the cooled reflux flow 56. The fourth flow 80 is subsequently reintroduced into the column 30 at a level N13 located below the level N12 and above the level N3, advantageously at the thirteenth stage from the top of the column 30.
In that manner, the flows 52, 72 and 96 are introduced into the upper portion of the column 30 which extends from a height greater than 35% of the height of the column 30, whilst the flows 56 and 68 are introduced into a middle portion which extends below the upper portion.
The column 30 produces at the bottom a liquid lower column flow 82. The lower column flow 82 has a temperature greater than 4° C. and in particular of 18.9° C.
In that manner, the lower flow 82 contains, in moles, 1.45% of carbon dioxide, 0% of nitrogen, 0.46% of methane, 45.83% of ethane, 26.80% of propane, 5.18% of i-butane, 10.96% of n-butane, 3.26% of i-pentane, 6.07% of n-pentane.
More generally, the flow 82 has a ratio C1/C2 of less than 3 mol %, for example, of 1%.
It contains more than 95 mol %, advantageously more than 99 mol % of the ethane contained in the supply flow 16 and it contains substantially 100 mol % of the C3+ hydrocarbons contained in the supply flow 16.
The lower column flow 82 is pumped in the pump 40 in order to form the cut 14 rich in C2+ hydrocarbons.
It may advantageously be reheated by being placed in a heat exchange relationship with at least one fraction of the supply flow 16 up to a temperature less than its bubble temperature, in order to keep it in liquid form.
The column 30 produces at the top a gaseous upper column flow 84 rich in methane. The flow 84 has a temperature less than −70° C. and particularly substantially of −108.9° C. It has a pressure substantially equal to the pressure of the column 30, for example, of 19.0 bar.
The upper flow 84 is successively introduced into the second heat exchanger 28, then into the first heat exchanger 20 in order to be reheated therein and to form a reheated upper flow 86 rich in methane. The flow 86 has a temperature greater than −10° C. and in particular of 27.5° C.
Subsequently, the flow 86 is introduced successively into the first compressor 32 driven by the main turbine 26 in order to be compressed therein to a pressure of substantially 40 bar, before being introduced into the first air cooler 34 in order to be cooled therein to a temperature less than 60° C., in particular of 40° C.
The partially compressed flow 88 obtained in this manner is introduced into the second compressor 36 then into the second cooler 38 in order to form a compressed upper flow 90. In that manner, the flow 90 has a pressure greater than 35 bar and particularly substantially of 63.1 bar.
The cooled upper column flow 90 substantially forms the flow rich in methane 12 produced by the method according to the invention.
Its composition is advantageously 97.19 mol % of methane, 2.39 mol % of nitrogen and 0.06 mol % of ethane. It further comprises more than 99% of the methane contained in the supply flow 16 and less than 5% of the C2+ hydrocarbons contained in the supply flow 16.
As illustrated in FIG. 1, an extraction flow 92 is removed from the compressed upper flow 90. The flow 92 has a non zero molar flow of between 0% and 35% of the molar flow of the compressed upper flow 90 upstream of the removal location, the remainder of the compressed upper flow 90 forming the flow 12.
The extraction flow 92 is cooled successively in the first exchanger 20, then in the second exchanger 28, before being subjected to pressure reduction in a fifth static pressure reduction valve 94.
The flow 96, which is substantially liquefied before pressure reduction in the valve 94, has, after pressure reduction, a liquid fraction greater than 0.8. The extraction flow 96 subjected to pressure reduction from the fifth valve 94 is subsequently introduced by reflux in the region of the top of the column 30 at a level N14 located above the level N1 and advantageously corresponding to the first stage of the column 30.
The temperature of the extraction flow 96 subjected to pressure reduction before it is introduced into the column 30 is less than −70° C. and is advantageously of −111.4° C.
Examples of temperature, pressure and molar flow of the different flows are set out in Table 1 below.












TABLE 1








Temperature
Pressure
Flow



Flow
(° C.)
(bar)
(kgmol/h)





















12
40.0
63.1
12950



14
19.4
24.2
2050



16
30.0
62.0
15000



42
−26.0
61.0
15000



44
−26.0
61.0
13472



45
−26.0
61.0
1528



46
−26.0
61.0
1350



48
−26.0
61.0
12122



49
−106.9
60.0
1350



52
−109.0
19.2
1350



54
−74.2
19.2
12122



56
−84.0
19.1
12122



60
−20.0
20.2
1528



62
−20.0
20.2
685



64
−20.0
20.2
843



68
−20.4
19.2
843



72
−106.9
19.2
685



82
18.9
19.2
2050



84
−108.9
19.0
15080



86
27.5
18.0
15080



88
40.0
25.1
15080



90
40.0
63.1
15080



92
40.0
63.1
2130



96
−111.4
19.2
2130










In relation to an installation of the prior art, as described, for example, in the American patent U.S. Pat. No. 6,578,379, the energy consumption of the method, constituted by the energy for driving the second compressor 36 is 13630 kW in comparison with 14494 kW with a method according to U.S. Pat. No. 6,578,379, wherein the same charge flow to be processed is used.
In relation to the prior art, therefore, the method according to the invention allows achievement of a substantial reduction in the power consumed, whilst maintaining strong selectivity for the extraction of ethane.
A second installation 110 according to the invention is illustrated in FIG. 2. That installation 110 is intended to carry out a second method according to the invention.
Unlike the first installation 10, the second installation 110 comprises a second dynamic pressure reduction turbine 112 coupled to a third compressor 114.
Unlike the first method according to the invention, the supply flow 16 is divided into a first supply flow fraction 115 and a second supply flow fraction 116.
The ratio of the molar flow of the first fraction 115 to the second fraction 116 is, for example, greater than 2 and is particularly between 2 and 15.
The first fraction 115 is directed to the first heat exchanger 20 in order to form the cooled fraction 42.
The second fraction 116 is directed to the second dynamic pressure reduction turbine 112 in order to be subjected to pressure reduction dynamically therein as far as a pressure of less than 40 bar, advantageously substantially equal to the pressure of the column 30.
The second supply fraction 118 subjected to pressure reduction and recovered at the outlet of the second pressure reduction turbine 112 thus has a temperature of less than 0° C. and particularly of −24° C. Thermal expansion in the turbine 112 allows 1364 kW to be recovered to cool the flow.
The fraction 118 is subsequently introduced into the second heat exchanger 28 in order to be cooled therein and at least partially liquefied. The cooled fraction 120 from the second exchanger 28 forms a second cooled reflux flow which is introduced into the column 30 at a higher level N15 located between the level N2 and the level N5, advantageously at the sixth stage from the top of the column 30.
The temperature of the second cooled reflux flow 120 is, for example, less than −70° C. and is particularly of −104.8° C.
According to the invention, the second cooled reflux flow 120 is formed from an effluent 118 of a dynamic pressure reduction turbine 112, that effluent 118 being cooled in the second heat exchanger 28 before being introduced into the column 30.
In a variant illustrated with broken lines in FIG. 2, the second fraction 116 is removed from the exchanger 20 in order to be partially cooled and partially liquefied therein.
The second fraction 116 is introduced into an upstream separation flask 122. The second fraction 116 is separated in the flask 122 into a second lower liquid fraction 124 and a second upper gas fraction 126.
The second lower fraction 124 is subjected to pressure reduction in a sixth static pressure reduction valve 128 as far as a pressure of less than 40 bar and substantially equal to the pressure of the column 30. It thereby forms a second liquid fraction 130 which is subjected to pressure reduction and which is introduced at a level N16 of the column 30 located between the level N11 and the level N8, advantageously at the fifteenth stage from the top of the column 30.
The second upper fraction 126 is introduced into the second dynamic pressure reduction turbine 112 in order to form the second supply fraction 118 subjected to pressure reduction.
The ratio of the molar flow of the second lower fraction 124 to the second upper fraction 126 is less than 0.2.
Furthermore, the reheated upper flow 86 is separated, at the outlet of the first heat exchanger 20, into a first reheated upper flow fraction 121A conveyed to the first compressor 32 and a second reheated upper flow fraction 121B conveyed to the third compressor 114. The fraction 121B is compressed in the third compressor 114 as far as a pressure greater than 15 bar.
The compressed fraction 121C obtained at the outlet of the third compressor 114 is mixed with the compressed fraction 121D obtained at the outlet of the first compressor 32, before they are introduced into the first cooler 34.
That parallel arrangement of the compressors 32, 114 allows a breakdown of one or other of the compressors to be overcome without having to completely stop the installation.
Examples of temperature, pressure and molar flow of the different flows are set out in Table 2 below.












TABLE 2








Temperature
Pressure
Flow



Flow
(° C.)
(bar)
(kgmol/h)





















12
−108.7
61.6
1588



14
15.3
22.9
2055



16
30.0
62.0
15000



42
−32.0
61.0
12500



44
−32.0
61.0
10936



45
−32.0
61.0
1564



46
−32.0
61.0
645



48
−32.0
61.0
10291



49
−108.7
60.0
645



52
−111.2
17.9
645



54
−81.4
18.4
10291



56
−85.0
17.9
10291



60
−35.0
36.5
1564



62
−35.0
36.5
448



64
−35.0
36.5
1116



68
−44.8
17.9
1116



72
−109.5
17.9
448



82
14.9
17.9
2055



84
−110.7
17.7
14534



86
25.1
16.7
14534



88
40.0
24.7
14534



90
40.0
63.1
14534



92
40.0
63.1
1588



96
−113.3
17.9
1588



115 
30.0
62.0
12500



116 
30.0
62.0
2500



118 
−24.0
18.9
2500



120 
−104.8
17.9
2500



 121C
61.6
25.2
3829



 121D
61.6
25.2
10704










The total consumption of the method is further reduced in relation to the first method according to the invention in order to be approximately 13392 kW.
In a variant which is not illustrated, the second compressor 36 comprises two compression stages which are separated by an air cooler. The arrangement obtained in this manner allows additional power economy of 884 kW.
The power consumed by the compressor 36 in accordance with the flow of the second supply flow fraction 116 is set out in Table 3 below.











TABLE 3





Recovery of
Flow to
Power of
Power of
Power of


ethane
turbine 112
turbine 26
turbine 112
compressor 36


mol %
kmol/h
kW
kW
kW



















99.20
1000
4111
546
13842


99.19
1500
3997
819
13567


99.20
2000
3904
1091
13446


99.18
2500
3812
1364
13392


99.19
3000
3721
1637
13425


99.20
3500
3631
1910
13534









According to this table, it is possible to obtain an increase in power of at least 7.6% in relation to the method described in the prior art.
Furthermore, for a flow ratio of between 4 and 6.5, between the flow of the first supply flow fraction 115 and the second supply flow fraction 116, a minimum level of power consumed is observed.
A third installation according to the invention 140 is illustrated in FIG. 3. That third installation is intended to carry out a third method according to the invention.
Unlike the second installation 110, the flow 54 from the first pressure reduction turbine 26 is conveyed directly by reflux into the column 30, at the level N2, without being cooled, particularly in the second heat exchanger 28.
Examples of temperature, pressure and molar flow of the different flows are set out in Table 4 below.












TABLE 4








Temperature
Pressure
Flow



Flow
(° C.)
(bar)
(kgmol/h)





















12
40.0
63.1
12951



14
16.7
23.2
2049



16
30.0
62.0
15000



42
−34.0
61.0
12000



44
−34.0
61.0
10392



45
−34.0
61.0
1608



46
−34.0
61.0
315



48
−34.0
61.0
10077



49
−108.3
60.0
315



52
−110.8
18.2
315



54
−83.7
18.2
10077



60
−35.0
36.0
1608



62
−35.0
36.0
503



64
−35.0
36.0
1104



68
−44.5
18.2
1104



72
−108.9
18.2
503



82
16.2
18.2
2049



84
−110.3
18.0
14821



86
23.6
17.0
14821



88
40.0
25.3
14821



90
40.0
63.1
14821



92
40.0
63.1
1870



96
−112.8
18.2
1870



115 
30.0
62.0
12000



116 
30.0
62.0
3000



118 
−23.5
19.2
3000



120 
−104.2
18.2
3000



 121C
60.4
25.8
4514



 121D
60.4
25.8
10307










A fourth installation 150 according to the invention is illustrated in FIG. 4. That fourth installation 150 is intended to carry out a fourth method according to the invention.
The fourth method is advantageously used for a supply flow 16 having heavy hydrocarbons which tend to solidify at low temperature. Those heavy hydrocarbons are, for example, of C6+. In that manner, the concentration of C6+ hydrocarbons is greater than 0.3 mol % in the supply flow 16.
An example of a supply flow 16 for carrying out the fourth method according to the invention comprises, in moles, 2.06% of nitrogen, 83.97% of methane, 6.31% of ethane, 3.66% of propane, 0.7% of isobutane, 1.5% of n-butane, 0.45% of isopentane, 0.51% of n-pentane, 0.19% of n-hexane, 0.10% of n-heptane, 0.03% of n-octane and 0.51% of carbon dioxide.
Unlike the third installation 140, the fourth installation 150 according to the invention comprises a downstream separation flask 152 which is positioned at the outlet of the second pressure reduction turbine 112.
In that manner, the fourth method according to the invention differs from the third method according to the invention in that the cooled and partially liquefied second supply fraction 118 is introduced into the downstream flask 152.
That fraction 118 is separated in the downstream flask 152 into a third lower liquid flow 154 and a third upper gas flow 156.
The third lower liquid flow 154 is introduced into a sixth static pressure reduction valve 128 in order to be subjected to pressure reduction therein and to form a third lower flow 158 subjected to pressure reduction.
The third lower flow 158 subjected to pressure reduction has a temperature greater than 0° C. and in particular of −23.3° C. It has a pressure substantially equal to the pressure of the column 30.
The third lower flow 158 subjected to pressure reduction is introduced into the column 30 at a level N16 located between the level N11 and the level N8, substantially at the thirteenth stage from the top of the column 30.
The third upper flow 156, which forms a portion of the effluent 118 from the second dynamic pressure reduction turbine 112 is introduced into the second exchanger 28 in order to be cooled and partially liquefied therein, before forming a third cooled reflux flow 160.
The temperature of the third cooled reflux flow 160 is less than −70° C. That cooled reflux flow 160 is introduced into the column 30 at the level N15.
The implementation of the fourth method according to the invention is further similar to that of the third method according to the invention.
Examples of temperature, pressure and molar flow of the different flows are set out in Table 5 below.












TABLE 5








Temperature
Pressure
Flow



Flow
(° C.)
(bar)
(kgmol/h)





















12
40.0
63.1
12948



14
16.3
23.2
2052



16
30.0
62.0
15000



42
−34.2
61.0
12000



44
−34.2
61.0
10397



45
−34.2
61.0
1603



46
−34.2
61.0
662



48
−34.2
61.0
9735



49
−108.3
60.0
662



52
−110.8
18.2
662



54
−84.0
18.2
9735



60
−35.0
36.0
1603



62
−35.0
36.0
495



64
−35.0
36.0
1108



68
−44.2
18.2
1108



72
−108.9
18.2
495



82
15.9
18.2
2052



84
−110.3
18.0
14597



86
25.1
17.0
14597



88
40.0
25.1
14597



90
40.0
63.1
14597



92
40.0
63.1
1649



96
−112.8
18.2
1649



115 
30
62.0
12000



116 
30.0
62.0
3000



118 
−23.0
19.2
3000



154 
−23.0
19.2
109



156 
−23.0
19.2
2891



158 
−23.3
18.2
109



160 
−104.5
18.2
2891



 121C
61.6
25.6
4577



 121D
61.6
25.6
10019










The reduction in the power consumed by the second compressor 36 in accordance with the flow introduced into the second dynamic pressure reduction turbine 112 is set out in Table 6 below.











TABLE 6





Recovery of
Flow to
Power of
Power of
Power of


ethane
turbine 112
turbine 26
turbine 112
compressor 36


mol %
kmol/h
kW
kW
kW



















99.19
1000
3994
539
13772


99.18
1500
3851
809
13518


99.18
2000
3745
1078
13444


99.20
2500
3641
1348
13288


99.18
3000
3558
1617
13170


99.18
3500
3483
1887
13216









The fourth method according to the invention advantageously allows processing of charges comprising compounds which become solidified at very low temperature, whilst maintaining an excellent efficiency level of extraction and consumption of energy which is very low.
A fifth installation according to the invention 170 is illustrated in FIG. 5. That fifth installation 170 is intended to carry out a fifth method according to the invention.
The fifth installation 170 differs from the first installation 10 in that it comprises a valve 172 for branching off a portion of the extraction flow 92 in order to branch off that portion upstream of the first dynamic pressure reduction turbine 26.
In the example illustrated in FIG. 5, the second compressor 36 further comprises two compression stages 36A, 36B which are separated by an air cooler 38A.
The implementation of the fifth method according to the invention differs from the implementation of the first method in that a make-up cooling flow 174 is removed from the extraction flow 25 obtained after it has been passed into the first heat exchanger 20. The ratio of the molar flow rate of the flow 174 to the molar flow rate of the extraction flow 25 before removal is between 5 and 50%.
The fifth method has a supply flow 16 whose content of C2+ hydrocarbons is advantageously greater than 15%.
An example of a composition of the flow 16 for carrying out the fifth method according to the invention comprises, in moles, 0.35% of nitrogen, 80.03% of methane, 11.33% of ethane, 3.60% of propane, 1.64% of isobutane, 2.00% of n-butane, 0.24% of isopentane, 0.19% of n-pentane, 0.19% of n-hexane, 0.10% of n-heptane, 0.03% of n-octane and 0.30% of carbon dioxide.
Since the temperature of the C2+ cut at the bottom of the distillation column 30 is substantially of −0.5° C., it is advantageously reheated.
The make-up cooling flow 174 is removed downstream of the first exchanger 20 and upstream of the second exchanger 28.
The flow 174 is introduced into the pressure reduction valve 172 in order to be subjected to pressure reduction therein as far as a pressure equivalent to that of the supply gas and to form a make-up cooling flow 176 subjected to pressure reduction. The flow 176 is reintroduced into the turbine supply fraction 48, upstream of the first dynamic pressure reduction turbine 26, and downstream of the separation location between the column supply fraction 46 and the turbine supply fraction 48.
The combination 178 of the flows 48 and 176 allows recovery of 5500 kW of energy in order to cool the effluent 54.
Furthermore, the partially compressed flow 88 is introduced into the first compression stage 36A in order to be compressed therein, then into the air cooler 38A, before being introduced into the second compression stage 36B.
That allows a substantial improvement in terms of power consumed to be achieved.
Examples of temperature, pressure and molar flow rate of the different flows are set out in Table 7 below.












TABLE 7








Temperature
Pressure
Flow



Flow
(° C.)
(bar)
(kgmol/h)





















12
40.0
63.1
12078



14
1.0
31.9
2922



16
40.0
62.0
15000



42
−24.0
61.0
15000



44
−24.0
61.0
12635



45
−24.0
61.0
2365



46
−24.0
61.0
2100



48
−24.0
61.0
10535



49
−112.3
60.0
2100



52
−112.0
15.0
2100



54
−82.4
15.0
12535



56
−93.3
15.0
12535



60
−38.0
39.7
2365



62
−38.0
39.7
423



64
−38.0
39.7
1942



68
−54.1
15.0
1942



72
−112.4
15.0
423



82
−0.5
15.0
2922



84
−114.4
14.8
15648



86
37.3
13.8
15468



88
40.0
19.9
15468



90
40.0
63.1
15468



92
40.0
63.1
3390



96
−115.6
15.0
1390



174
−45.0
62.6
2000



176
−46.1
61.0
2000



178
−27.4
61.0
12535










The reduction of the power of the second compressor 36 in accordance with the flow recycled to the first dynamic pressure reduction turbine 26 is illustrated by Table 8 below.











TABLE 8





Recovery of
Flow to
Power of
Temperature of
Power of


ethane
turbine 26
turbine 26
flow 56
compressor 36


mol %
kmol/h
kW
° C.
kW



















99.18
0
5383
−85.7
17506


99.19
200
5419
−85.7
17159


99.18
500
5444
−86.7
16967


99.20
800
5459
−88.2
16847


99.19
1100
5475
−89.7
16758


99.18
1700
5493
−92.1
16658


99.17
2000
5499
−93.2
16650


99.19
2100
5498
−93.6
16665









A reduction of 4.9% in the power of the second compressor 36 is observed in relation to the first method according to the invention, which itself represents an increase of 5.2% in relation to the prior art carried out on that heavy gas.
A sixth installation according to the invention is illustrated in FIG. 6. That sixth installation 180 differs from the fifth installation 150 owing to the presence of a downstream dynamic pressure reduction turbine 182 coupled to a downstream compressor 184.
Unlike the fifth method according to the invention, an auxiliary pressure reduction flow 186 is removed from the compressed upper flow 90 from the air cooler 38 parallel with the extraction flow 92.
The auxiliary pressure reduction flow 186 is conveyed to the downstream dynamic pressure reduction turbine 182 in order to be subjected to pressure reduction at that location to a pressure less than 40 bar and substantially of 15.3 bar.
The auxiliary pressure reduction flow 188 subjected to pressure reduction from the turbine 182 is subsequently reintroduced into the upper flow 190, upstream of the first heat exchanger 20 and downstream of the second heat exchanger 28.
Furthermore, as in the fourth method according to the invention, the flow 86 from the first heat exchanger 20 is separated into a first recompression fraction 121A which is conveyed to the first compressor 32 and a second compression fraction 121B which is conveyed to the downstream compressor 184.
The ratio of the molar flow rate of the auxiliary pressure reduction flow 186 to the compressed upper flow 90 from the cooler 38 is less than 30% and is substantially between 10 and 30%.
Examples of temperature, pressure and molar flow rate of the different flows are set out in Table 9 below.












TABLE 9








Temperature
Pressure
Flow



Flow
(° C.)
(bar)
(kgmol/h)





















12
40.0
63.1
12076



14
3.8
31.9
2924



16
40.0
62.0
15000



42
−31.0
61.0
15000



44
−31.0
61.0
11946



45
−31.0
61.0
3054



46
−31.0
61.0
1905



48
−31.0
61.0
10041



49
−110.9
60.0
1905



52
−110.7
16.0
1905



54
−82.4
16.0
10091



56
−89.9
15.9
10091



60
−38.0
39.7
3054



62
−38.0
39.7
795



64
−38.0
39.7
2259



68
−53.7
16.0
2259



72
−110.5
16.0
795



82
2.4
16.0
2924



84
−112.9
15.8
13126



86
33.5
14.8
16126



88
40
22.1
16126



90
40.0
63.1
16126



92
40.0
63.1
1050



96
−114.0
16.0
1000



174 
−45.0
62.6
50



176 
−46.1
61.0
50



178 
−31.1
61.0
10091



186 
40.0
63.1
3000



188 
−43.4
15.3
3000



190 
−43.4
15.3
16126



 121C
71.5
22.6
5328



 121D
71.5
22.6
10798










The reduction in the power of the compressor 36 in accordance with the flow conveyed to the first turbine 32 and the flow conveyed to the downstream turbine 182 is described in Table 10 below.
The total consumption of the method is further reduced in relation to the fifth method according to the invention in order to be 15716 kW, whereas that consumption was 16650 kW for the fifth method according to the invention.












TABLE 10





Flow
Power






recycled
of
Flow at
Power of
Pressure
Power of


to
turbine
auxiliary
turbine
of
compressor


turbine 26
26
turbine 182
182
column 30
36


kmol/h
kW
kmol/h
kW
bar
kW




















2000
5499
0
0
15
16650


1200
4733
1500
1031
15.4
16221


50
4085
3000
2015
16
15716









The recovery of ethane is substantially equal to 99.18% in the three cases.
In a variant, the installation 180 comprises a second branching valve 192 which is capable of conveying a portion of the flux 54 to the column 30 without being cooled, particularly in the second heat exchanger 28.
A fraction of the flow 54 can therefore be removed and pass into the valve 192 before being reintroduced into the fraction 56.
A seventh installation 200 according to the invention is illustrated in FIG. 7. Unlike the fifth installation 170 illustrated in FIG. 5, the seventh installation comprises, as in the fourth installation 150, a downstream separation flask 152 which receives the second supply fraction 118 subjected to pressure reduction after it has been passed into the second pressure reduction turbine 112.
As in the fourth installation 150, the third upper flow 156 passes into the second exchanger 28 in order to be cooled and partially liquefied therein and to form a cooled reflux flow 160.
The lower flow 154 from the downstream flask 152 is subjected to pressure reduction in the sixth static pressure reduction valve 128 in order to form a flow 158 which is subjected to pressure reduction and which is introduced into a lower portion of the column 30.
As in the sixth installation 180, the installation comprises a branch which is provided with a valve 192 which allows a portion of the effluent 54 from the first turbine 26 to be passed directly into the column 30 without passing via the second exchanger 28.
The seventh method is further carried out in a manner similar to that of the fifth method according to the invention.
Examples of temperature, pressure and molar flow are set out in Table 11 below.












TABLE 11







Flow
Temperature
Pressure
Flow



b
(° C.)
(bar)
(kgmol/h)





















12
40.0
63.1
12075



14
−2.2
32.0
2925



16
40.0
62.0
15000



25
−42.0
62.6
2710



42
−31.7
61.0
12000



44
−31.7
61.0
9498



45
−31.7
61.0
2502



46
−31.7
61.0
257



48
−31.7
61.0
9241



49
−114.0
60.0
257



52
−114.2
14.0
257



54
−89.4
14.0
10441



56
−89.4
14.0
10441



60
−36.0
36.0
2502



62
−36.0
36.0
828



64
−36.0
36.0
1674



68
−50.9
14.0
1674



72
−113.6
14.0
828



82
−3.7
14.0
2925



84
−116.0
13.8
14785



86
30.9
12.8
14785



88
40.0
20.5
14785



90
40.0
63.1
14785



92
40.0
63.1
2710



96
−117.3
14.0
1510



115 
40.0
62.0
12000



116 
40.0
62.0
3000



118 
−25.3
14.5
3000



154 
−25.3
14.5
118



156 
−25.3
14.5
2882



158 
−25.5
14.0
118



160 
−108.8
14.0
2882



174 
−42.0
62.6
1200



176 
−43.0
61.0
1200



178 
−33.0
61.0
10441



 121C
75.3
21
4566



 121D
75.3
21
10220










The reduction in the power of the second compressor 36 in accordance with the increase in the flow recycled to the first pressure reduction turbine 26, fixing the flow recycled to the second pressure reduction turbine 112, is illustrated by Table 12 below.











TABLE 12






Flow


Flow at


Recovery of
recycled to
Power of
Power of
auxiliary


ethane
turbine 26
turbine 26
compressor 36
turbine 112


mol %
kmol/h
kW
kW
kmol/h



















99.20
700
4491
15763
3000


99.19
1000
4531
15530
3000


99.20
1200
4543
15507
3000


99.19
1500
4578
15596
3000









It is possible to establish a reduction of 6.9% in the power supplied to the second compressor 36 relative to the installation illustrated in FIG. 5.
An eighth installation 210 according to the invention is illustrated in FIG. 8. That eighth installation 210 is intended to carry out an eighth method according to the invention.
The eighth installation 210 is advantageously intended to increase the capacity of an installation of the type which is described in the U.S. Pat. No. 6,578,379 and which comprises the first heat exchanger 20, the first separation flask 22, the second separation flask 24, the distillation column 30, the first compressor 32 coupled to the first pressure reduction turbine 26 and the second compressor 36.
As in the installation illustrated in FIG. 4, the eighth installation 210 further comprises a second dynamic pressure reduction turbine 112 and a third compressor 114, and a downstream flask 152 for receiving the effluent of the second dynamic pressure reduction turbine 112. The installation 210 further comprises an upstream heat exchanger 212, a downstream heat exchanger 214 and an auxiliary distillation column 216 provided with an auxiliary bottom pump 218.
The eighth installation 210 also comprises a fourth compressor 220 interposed between two air coolers 222A, 222B.
The eighth method according to the invention differs from the fourth method according to the invention in that the supply flow 16 is further separated into a third supply flow fraction 224 which is introduced into the upstream heat exchanger 212, before forming, with the first fraction 115 from the exchanger 20, the first cooled fraction 42.
The ratio of the molar flow rate of the third fraction 224 to the molar flow rate of the supply flow 16 is greater than 5%.
Unlike the fourth method, the third upper flow 156 from the downstream flask 152 is introduced into the downstream heat exchanger 214 in order to be cooled therein to a temperature less than −70° C. and to form the third cooled upper flow 160.
The third cooled upper flow 160 is introduced into the auxiliary column 216 at a lower stage E1.
The column 216 has a number of theoretical stages less than the number of theoretical stages of the column 30. That number of stages is advantageously between 1 and 7. The auxiliary column 216 operates at a pressure which is substantially equal to that of the column 30.
The lower flow 158 subjected to pressure reduction and obtained after pressure reduction of the lower flow 154 in the valve 128 and the lower liquid fraction 68 obtained after pressure reduction of the lower fraction 64 in the valve 66 are mixed upstream of the column 30 in order to be introduced at the same location in the column 30. The two mixed flows 226 are introduced into the column 30 at a level N3 advantageously corresponding to the twelfth stage from the top of the column 30.
The upper vapour fraction 62 from the second separation flask 24 is introduced, after passage in the valve 70, at a middle stage E2 of the auxiliary column 216 located above the stage E1.
A first portion 226 of the fraction 52 subjected to pressure reduction in the valve 50 is introduced into the auxiliary column 216 at a stage E3 located above the level E2. A second portion 228 of the fraction 52 is introduced directly into the column 30 at the level N1.
The auxiliary column 216 produces an upper auxiliary flow 230 rich in methane and a lower auxiliary flow 232.
The upper auxiliary flow 230 is mixed with the upper flow 84 rich in methane produced by the distillation column 30.
The lower flow 232 is pumped by the auxiliary pump 218 in order to form a cooled reflux flow 234 which is introduced into the column 30 at the level N5.
Therefore, the flow 234 constitutes a cooled reflux flow which is obtained from a portion of an effluent 118 of a dynamic pressure reduction turbine 112, after separation of that effluent.
The mixture 235 of the upper flows 84 and 230 is separated into a first main upper flow fraction 236 and a second lesser upper flow fraction 238.
The ratio of the molar flow rate of the main fraction 236 to the lesser fraction 238 is greater than 1.5.
The main fraction 236 is introduced successively into the second heat exchanger 28, then into the first heat exchanger 20, in order to form the upper reheated flow 86 introduced into the first compressor 32.
The second upper flow fraction 238 is passed into the downstream heat exchanger 214 with counterflow of the third upper flow 156 in order to become reheated therein up to a temperature greater than −50° C. and to form a second reheated fraction 240.
The second reheated fraction 240 is subsequently separated into a return flow 242 and a compression flow 244.
The return flow 242 is reintroduced into the first upper flow fraction 236, downstream of the second exchanger 28 and upstream of the first exchanger 20 in order to partially form the reheated upper flow 86.
The recompression flow 244 is subsequently introduced into the upstream exchanger 212 in order to cool the third fraction of the supply flow 224. The flow 244 becomes heated up to a temperature greater than −10° C. in order to form a reheated recompression flow 246.
A first portion 248 of the recompression flow 246 is mixed with the first fraction of the upper flow 236, downstream of the first heat exchanger 20 in order to form the reheated upper flow 86.
A second portion 250 of the recompression flow 246 is introduced into the third compressor 114, then into the air cooler 222A, before being recompressed in the fourth compressor 220 and being introduced into the air cooler 222B.
The second compressed portion 252 from the air cooler 222B has a temperature of less than 60° C. and in particular substantially of 40° C. and a pressure of greater than 35 bar and in particular of 63.1 bar.
That first compressed portion 252 is mixed with the compressed upper flow 90 downstream of the tapping location of the extraction flow 92 in order to form the flow rich in methane 12.
Unlike the first method, the heat exchanger 20 does not receive any reboiling flow from the column 30.
In a variant illustrated partially with broken lines in FIG. 8, an auxiliary cooling flow 174 is removed from the extraction flow 92 upstream of the exchanger 28 as in the fifth method according to the invention.
Therefore, the eighth installation 210 and the eighth method according to the invention allow an increase in the capacity of an installation of the existing prior art in order to increase the flow rate of the supply flow 16, without having to modify the existing equipment of the installation, and particularly keeping the heat exchangers 20, 28, the column 30, the compressors 32, 36 and the turbine 26 identical and using the inlets already present in the column 30.
Examples of temperature, pressure and molar flow rate of the different flows are set out in Table 13 below, for a charge comprising, in moles, 2.06% of nitrogen, 83.97% of methane, 6.31% of ethane, 3.66% of propane, 0.71% of isobutane, 1.49% of n-butane, 0.44% of iso-pentane, 0.5% of n-pentane, 0.19% of n-hexane, 0.10% of n-heptane, 0.03% of n-octane and 0.5% of carbon dioxide.












TABLE 13








Temperature
Pressure
Flow



Flow
(° C.)
(bar)
(kgmol/h)





















12
40.0
63.1
14880



14
14.0
22.6
2367



16
30.0
62.0
17250



42
−31.0
61.0
13950



44
−31.0
61.0
12280



45
−31.0
61.0
1671



46
−31.0
61.0
1689



48
−31.0
61.0
10590



49
−109.8
60.0
1689



54
−82.0
17.6
10590



60
−36.0
44.0
1671



62
−36.0
44.0
299



64
−36.0
44.6
1372



68
−47.8
17.6
1372



72
−110.8
17.6
299



82
13.6
17.6
2367



84
−111.3
17.4
14498



86
27.6
16.4
14350



88
40.0
22.3
14350



90
40.0
63.1
14350



92
40.0
63.1
2100



96
−113.7
17.6
2100



115
30.0
62.0
12450



116
30.0
62.0
3300



118
−24.2
18.6
3300



154
−24.2
18.6
122



156
−24.2
18.6
3178



158
−24.5
17.6
122



160
−100.7
17.6
3178



224
30.0
62.0
1500



226
−111.6
17.6
1679



228
−111.6
17.6
10



230
−109.6
17.6
2485



232
−106.0
17.7
2672



235
−111.1
17.4
16983



236
−111.1
17.4
11306



238
−111.1
17.4
5677



240
−30.7
16.9
5677



242
−30.7
16.9
2302



244
−30.7
16.9
3375



246
18.7
16.4
3375



248
18.7
16.4
745



250
18.7
16.4
2630



252
40.0
63.1
2630










Table 14 below illustrates the progressive increase in the flow rate of the supply flow 16. The recovery of C2+ in the flow 14 is greater than 99% and substantially of 99.1%. The power of the compressor 36 is kept constant at 14896 kW.












TABLE 14







Flow to

Power of




Power of
turbine
Power of
compressor
Pressure of


Supply
turbine 26
112
turbine 112
220
column 30


flow %
kW
kgmol/h
kW
kW
Bar a




















100
4382
0
0
0
18.0


109
4160
2000
1086
529
18.0


115
4095
3300
1832
1415
17.4


120
4131
3950
2256
2588
16.7









In order to conserve the same recovery of C2+ as the existing unit, the pressure of the column 30 is slightly reduced. The presence of the new compressor 220 allows the power of the second compressor 36 to be kept the same, in spite of the flow increase.
Furthermore, the capacity of the first pressure reduction turbine 26 has been kept constant. The turbine 112 is used to process the addition of capacity.
The presence of an auxiliary column 216 also allows prevention of blockage of the column 30 during the increase of flow. The presence of the auxiliary flask 152 further prevents the problem of coagulation of the heavy elements contained in the supply flow.
In a variant, the eighth installation 210 according to the invention allows processing of a supply flow 16 containing more C2+ hydrocarbons.
Such a flow has, for example, a composition comprising, in moles, 1% of nitrogen, 86.25% of methane, 5.78% of ethane, 2.99% of propane, 0.71% of isobutane, 1.49% of n-butane, 1.28% of C5+ hydrocarbons and 0.5% of carbon dioxide, which constitutes the initial charge which will subsequently be supplemented with C2+, in accordance with Table 15 below.
More generally, the enriched composition has more than 1 mol % of C5+ hydrocarbons.
The eighth installation according to the invention allows retention of recovery of ethane that is greater than 99%, in particular of 99.2%, and a temperature and a pressure of the supply flow 16 that are substantially the same. Similarly, the associated pressure drops in the equipment, the efficiency of the plates in the column 30 and the position of the extractions, the maximum specification of methane of the lower flow 82 of the column 30, the efficiency levels of the turbines and compressors, the power of the second compressor 36 and the existing turbine 26 and the heat exchange coefficients of the existing exchangers 20 and 28 are kept the same.
As illustrated in Table 15 below, it is possible to maintain a recovery of C2+ that is substantially identical to that of the prior art in spite of the increase in the content of C2+ hydrocarbons.
The recovery of C2+ from the flow 12 is greater than 99 mol %, advantageously of 99.2 mol %. The power of the compressor 36 is kept constant at 13790 kW. The pressure of the column 30 slightly decreases with the increase in the content of C2+, from 19.0 bar to 18.6 bar then to 17.8 bar.











TABLE 15





Flow of cut
Power of
Flow to
Power of
Power of


14 rich in C2+
turbine 26
turbine 112
turbine 112
compressor 220


kgmol/h
kW
kgmol/h
kW
kW



















1872
4111
0
0
0


1970
4024
950
502
0


2051
3829
1840
1005
383









In this manner, the new compressor 220 allows a processed gas 12 that is rich in methane to be obtained under the same conditions as in the prior art.
In a variation of FIGS. 5 and 6, the installation comprises a second dynamic pressure reduction turbine 112, as shown in FIG. 2, 3, 4, 7 or 8.
The supply flow 116 is then separated into a first fraction 115 of the supply flow and a second fraction 116 of the supply flow, which follows the path disclosed above in reference to any of FIG. 2, 3, 4, 7 or 8.

## Claims

1. A method of producing a flow rich in methane and a flow rich in C2+ hydrocarbons from a supply flow containing hydrocarbons, the method comprising the following steps:
separating the supply flow into a first fraction of the supply flow and at least a second fraction of the supply flow;
introducing the first fraction of the supply flow into a first heat exchanger;
cooling the first fraction of the supply flow in the first heat exchanger;
introducing the cooled first fraction of the supply flow into a first separation flask in order to produce a light upper flow and a heavy lower flow;
dividing the light upper flow into a turbine supply fraction and a column supply fraction;
pressure reducing the turbine supply fraction in a first dynamic pressure reduction turbine and introducing at least a portion of the turbine supply fraction subjected to pressure reduction into the first turbine in a middle portion of a first distillation column;
cooling and at least partially condensing the column supply fraction and pressure reducing and introducing the cooled column supply fraction into an upper portion of the first distillation column;
pressure reducing and partial vaporizing the heavy lower flow in the first heat exchanger and introducing the heavy lower flow subjected to pressure reduction into a second separation flask in order to produce an upper gas fraction and a lower liquid fraction;
pressure reducing the lower liquid fraction and introducing the lower liquid fraction in the middle portion of the first distillation column;
cooling and at least partially condensing the upper gas fraction and introducing the upper gas fraction into the upper portion of the first distillation column;
recovering a lower column flow at the bottom of the first distillation column, the flow rich in C2+ hydrocarbons being formed from the lower column flow;
recovering and reheating of an upper column flow rich in methane;
compressing at least a fraction of the upper column flow in at least a first compressor coupled to the first dynamic pressure reduction turbine and in at least a second compressor;
removing an extraction flow from the reheated and compressed upper column flow;
cooling and introducing the cooled extraction flow into an upper portion of the first distillation column;
introducing at least a portion of the second fraction of the supply flow into a second dynamic pressure reduction turbine, separate from the first dynamic pressure reduction turbine;
forming an effluent from the second dynamic pressure reduction turbine;
cooling and at least partly liquefying at least a portion of the effluent from the second dynamic pressure reduction turbine in a second heat exchanger so as to form a cooled reflux flow; and
introducing the cooled reflux flow from the second heat exchanger into the first distillation column,
wherein the portion of the second fraction of the supply flow introduced into the second dynamic pressure reduction turbine is conveyed from the separation point of the supply flow to the second dynamic pressure reduction turbine without passing through any heat exchanger.

2. The method according to claim 1, further comprising:
removing a reboiling flow from the first distillation column at a removal level;
placing the reboiling flow in a heat exchange relationship with the portion of the effluent from the second dynamic pressure reduction turbine in the second heat exchanger in order to cool and at least partially liquefy the portion of the effluent from the second dynamic pressure reduction turbine; and
reintroducing the reboiling flow into the first distillation column at a level lower than the removal level.

3. The method according to claim 1, wherein the method comprises introducing the fraction subjected to pressure reduction from the first dynamic pressure reduction turbine into the second heat exchanger in order to be cooled and partially liquefied therein, the cooled fraction forming an auxiliary cooled reflux stream; and
introducing the auxiliary cooled reflux stream in the first distillation column.

4. The method according to claim 1, further comprising:
introducing the effluent from the second dynamic pressure reduction turbine into a downstream separation flask in order to form a third upper gas flow and a third lower liquid flow; and
cooling the third upper gas flow in the second heat exchanger in order to form the cooled reflux flow.

5. The method according to claim 1, wherein an entirety of the second fraction of the supply flow is introduced into the second dynamic pressure reduction turbine.

6. The method according to claim 1, wherein the method comprises:
removing a secondary compression fraction from the upper column flow rich in methane, before the upper column flow rich in methane is passed into the first compressor;
passing the secondary compression fraction into a third compressor coupled to the second dynamic pressure reduction turbine; and
introducing the compressed secondary compression fraction from the third compressor into the compressed upper column flow, downstream of the first compressor.

7. The method according to claim 1, comprising:
removing a make-up cooling flow from the upper column flow rich in methane or from a flow formed from the upper column flow rich in methane; and
pressure reducing and introducing the make-up cooling flow subjected to pressure reduction into a flow flowing upstream of the first pressure reduction turbine.

8. The method according to claim 1, wherein the second compressor comprises a first compression stage, at least a second compression stage, and a cooler interposed between the first compression stage and the second compression stage, the method comprising:
a step of passing the compressed upper column flow from the first compressor successively into the first compression stage, into the cooler, and then into the second compression stage.

9. The method according to claim 1, wherein the portion of the effluent from the second dynamic pressure reduction turbine, the upper column flow, the column supply fraction and the upper gas fraction are placed in a heat exchange relationship in the second heat exchanger.

10. The method according to claim 7, wherein the make-up cooling flow is introduced into the turbine supply fraction.

11. The method according to claim 1, wherein the cooling and at least partially condensing of the column supply fraction is carried out in the second heat exchanger,
the cooling and at least partially condensing the upper gas fraction being carried out in the second heat exchanger.

12. An installation for producing a flow rich in methane and a flow rich in C2+ hydrocarbons from a supply flow containing hydrocarbons, the installation comprising:
a supply flow separator configured to separate the supply flow into a first fraction of the supply flow and at least a second fraction of the supply flow;
a first heat exchanger configured to cool the first fraction of the supply flow;
a first heat exchange introducer configured to introduce the first fraction of the supply flow into the first heat exchanger;
a first separation flask and a first separation flask introducer configured to introduce the cooled first fraction of the supply flow into the first separation flask in order to produce a light upper flow and a heavy lower flow;
a light upper flow divider configured to divide the light upper flow into a turbine supply fraction and a column supply fraction;
a first distillation column;
a turbine supply fraction pressure reducer configured to reduce a pressure of the turbine supply fraction comprising a first dynamic pressure reduction turbine and a first turbine introducer configured to introduce at least a portion of the fraction subjected to pressure reduction into the first turbine in a middle portion of the first distillation column;
a column supply fraction processor configured to cool and at least partially to condense the column supply fraction comprising a second heat exchanger and a cooled column supply fraction pressure reducer configured to reduce pressure of the cooled column supply fraction and to introduce the cooled column supply fraction into an upper portion of the first distillation column;
a heavy lower flow processing unit configured to pressure reduce and to partially vaporize the heavy lower flow comprising the first heat exchanger;
a second separation flask and a second separation flask introducer configured to introduce the heavy lower flow into the second separation flask in order to produce an upper gas fraction and a lower liquid fraction;
a pressure reducer configured to pressure reduce the lower liquid fraction and a first distillation column introducer configured to introduce the reduced pressure lower liquid fraction into the middle portion of the first distillation column;
an upper gas fraction cooler and condenser unit configured to cool and at least partially to condense the upper gas fraction comprising the second heat exchanger and an introducer configured to introduce the upper gas fraction into the upper portion of the first distillation column;
a lower column flow recovery unit configured to recover a lower column flow at the bottom of the first distillation column, and a former configured to form the flow rich in C2+ hydrocarbons from the lower column flow;
an upper column flow recovery and reheating unit configured to recover and to reheat an upper column flow rich in methane, at the top of the first distillation column;
a compressor unit configured to compress at least a fraction of the upper column flow comprising at least a first compressor coupled to the first dynamic pressure reduction turbine and at least a second compressor;
a removal unit configured to remove from the reheated and compressed upper column flow an extraction flow,
an introducer configured to introduce the extraction flow in the first and second heat exchanger and the cooled extraction flow into an upper portion of the first distillation column;
a second dynamic pressure reduction turbine separate from the first dynamic pressure reduction turbine;
a second turbine introducer configured to introduce at least a portion of the second fraction of the supply flow into the second dynamic pressure reduction turbine;
an effluent former configured to form an effluent from the second dynamic pressure reduction turbine;
the second heat exchanger being able to cool and at least partly liquefy at least a portion of the effluent from the second dynamic pressure reduction turbine in order to form a cooled reflux flow; and
a reflux introducer configured to introduce the cooled reflux flow from the second heat exchanger into the first distillation column,
wherein the portion of the second fraction of the supply flow introduced into the second dynamic pressure reduction turbine is conveyed from the separation point of the supply flow to the second dynamic pressure reduction turbine without passing through a heat exchanger.

13. The installation according to claim 11, comprising: a second heat exchanger introducer configured to introduce the fraction subjected to pressure reduction from the first dynamic pressure reduction turbine into the second heat exchanger in order to be cooled and partially liquefied therein, the cooled fraction forming an auxiliary cooled reflux stream; and
an auxiliary reflux stream introducer configured to introduce the auxiliary cooled reflux stream in the first distillation column.

14. The installation according to claim 12, wherein the column supply fraction processor comprises the second heat exchanger, the upper gas fraction cooler and condenser unit comprising the second heat exchanger.