Process for liquefying methane

Claim 2

In a liquefaction process for natural gas wherein heavy hydrocarbons can be separated and recovered in which the natural gas is initially cooled against a first, high level refrigerant before being passed to a scrub column for separation of at least some heavy hydrocarbons and is then subsequently cooled, liquefied and subcooled against a second, low level refrigerant in a main heat exchanger, the improvement comprising providing liquid reflux to the scrub column by expanding the precooled natural gas feed isentropically while obtaining mechanical energy and delivering the expanded feed to the top of said scrub column as a feed and as all of the reflux to said column while removing a methane-rich overhead from said column and recompressing it in a compressor driven by said expander and delivering the recompressed methane-rich overhead stream directly to the main heat exchanger for liquefaction as product.

Claim 3

A liquefaction process for natural gas including the separation in a scrub column of heavier hydrocarbons as a bottom stream from a methane-rich fraction as an overhead stream, comprising the steps of: (a) introducing a natural gas feed stream into the liquefaction system at a pressure in the range of 600-2000 psia; (b) cooling the feed stream in a series of heat exchangers in indirect heat exchange with a first refrigerant in a closed refrigeration system; (c) reducing the pressure of the feed stream to a pressure which is below the critical pressure of both the overhead and bottom streams by isentropically expanding said feed stream while obtaining mechanical energy; (d) introducing the expanded feed stream as feed and as all of the reflux to the scrub column to separate the methane-rich fraction as an overhead stream; (e) compressing the overhead stream to a high pressure in a compressor utilizing the mechanical energy derived from the expansion of step (c); (f) cooling, liquefying and subcooling the methane-rich stream in a heat exchanger by indirect heat exchange with a second, multi-component, refrigerant in a closed refrigeration system; (g) withdrawing said liquefied and subcooled methane-rich stream as an LNG product.

Claim 4

A liquefaction process for natural gas including the separation in a scrub column of heavier hydrocarbons as a bottom stream from a methane-rich fraction as an overhead stream, comprising the steps of: (a) introducing a natural gas feed stream into the liquefaction system at a pressure in the range of 600-2000 psia; (b) cooling the feed stream in a series of heat exchangers in indirect heat exchange with a first refrigerant in a closed refrigeration system; (c) reducing the pressure of the feed stream to a pressure which is below the critical pressure of both the overhead and bottom streams by isentropically expanding said feed stream while obtaining mechanical energy; (d) introducing the expanded feed stream as feed and as all of the reflux to the scrub column to separate the methane-rich fraction as an overhead stream; (e) compressing the overhead stream to a high pressure in a compressor utilizing the mechanical energy derived from the expansion of step (c); (f) cooling, liquefying and subcooling the methane-rich stream in a heat exchanger by indirect heat exchange with a second, multi-component, refrigerant in a closed refrigeration system; (g) withdrawing said liquefied and subcooled methane-rich stream as an LNG product.

Claim 5

A liquefaction process for natural gas including the separation in a scrub column of heavier hydrocarbons as a bottom stream from a methane-rich fraction as an overhead stream, comprising the steps of: (a) introducing a natural gas feed stream into the liquefaction system at a pressure in the range of 600-2000 psia; (b) cooling the feed stream in a series of heat exchangers in indirect heat exchange with a first refrigerant in a closed refrigeration system; (c) reducing the pressure of the feed stream to a pressure which is below the critical pressure of both the overhead and bottom streams by a combination of isentropically expanding said feed stream while obtaining mechanical energy and intercooling at least a portion of the feed stream against the methane-rich overhead stream from the scrub column; (d) introducing the intercooled and expanded feed stream as feed and as all of the reflux to the scrub column to separate the methane-rich fraction as an overhead stream and the heavier hydrocarbon fraction as a bottom stream; (e) warming the methane-rich overhead stream in an intercooling heat exchange against the intercooling feed stream of step (c); (f) compressing the warmed overhead stream to a high pressure in a compressor utilizing the mechanical energy derived from the expansion of step (c); (g) cooling, liquefying and subcooling the methane-rich stream in a heat exchanger by indirect heat exchange with a second, multi-component, refrigerant in a closed refrigeration system; (h) withdrawing said liquefied and sub-cooled methane-rich stream as an LNG product.

Claim 6

A liquefaction process for natural gas including the separation in a scrub column of heavier hydrocarbons as a bottom stream from a methane-rich fraction as an overhead stream, comprising the steps of: (a) introducing a natural gas feed stream into the liquefaction system at a pressure in the range of 600-2000 psia; (b) cooling the feed stream in a series of heat exchangers in indirect heat exchange with a first refrigerant in a closed refrigeration system; (c) reducing the pressure of the feed stream to a pressure which is below the critical pressure of both the overhead and bottom streams by a combination of isentropically expanding said feed stream while obtaining mechanical energy and intercooling at least a portion of the feed stream against the methane-rich overhead stream from the scrub column; (d) introducing the intercooled and expanded feed stream as feed and as all of the reflux to the scrub column to separate the methane-rich fraction as an overhead stream and the heavier hydrocarbon fraction as a bottom stream; (e) warming the methane-rich overhead stream in an intercooling heat exchange against the intercooling feed stream of step (c); (f) compressing the warmed overhead stream to a high pressure in a compressor utilizing the mechanical energy derived from the expansion of step (c); (g) cooling, liquefying and subcooling the methane-rich stream in a heat exchanger by indirect heat exchange with a second, multi-component, refrigerant in a closed refrigeration system; (h) withdrawing said liquefied and sub-cooled methane-rich stream as an LNG product.

Claim 7

The invention of claim 3 wherein a medium pressure natural gas feed stream at 600-1100 psia is processed in which, after the initial cooling, the feed is phase separated to remove a liquid bottom stream which is introduced to the scrub column as intermediate feed and a gaseous overhead stream which is intercooled against the methane-rich overhead stream and further phase separated wherein the liquid phase is again introduced as an intermediate feed to the scrub column and the gaseous phase is expanded isentropically with the production of mechanical energy before being introduced into the scrub column as reflux, and the methane-rich overhead stream from the scrub column, after compression, is cooled by indirect heat exchange with the first refrigerant before being liquefied and subcooled to LNG by heat exchange with the second refrigerant.

Claim 8

The invention of claim 3 wherein a high pressure natural gas feed stream at 1000 to 2000 psia is processed in which after the initial cooling, the feed is isentropically expanded with the production of mechanical energy and then intercooled against the methane-rich overhead stream before the feed is introduced as reflux to the scrub column.

Claim 9

The invention of claim 3 wherein a high pressure natural gas feed stream at 1000 to 2000 psia is processed in which after the initial cooling, the feed is intercooled by heat exchange against the methane-rich overhead stream before being isentropically expanded and said methane-rich overhead stream, after compression, is cooled by indirect heat exchange with the first refrigerant before being further cooled, liquefied and sub-cooled by heat exchange against the second refrigerant.

Claim 10

The invention of claims 3, 4, 5 or 6 wherein the liquefied product of step (g) is phase separated to produce a liquid bottom stream for delivery as LNG product for storage and a gaseous overhead which is warmed by indirect heat exchange with the second refrigerant to recover refrigeration value from the gaseous overhead before said overhead is used as a plant fuel.