Process for separating hydrogen and methane from an ethylene rich stream

Claim 2

A process for separating hydrogen and methane from a gas mixture containing hydrocarbons heavier than methane, said process comprising the steps of: providing the option of precluding the need to utilize an external methane refrigeration circuit by, passing the mixture through a plurality of chilling stages; collecting at least one chilling stage bottoms portion from at least one of the plurality of chilling stages; passing at least one chilling stage bottoms portion to a hydrogen stripper; collecting a hydrogen stripper overheads portion containing most of the hydrogen entering the hydrogen stripper; collecting a hydrogen stripper bottoms portion containing most of the methane and at least ninety-nine mole percent of the hydrocarbons heavier than methane passed to the hydrogen stripper; passing the hydrogen stripper bottoms portion to a fractionation zone; collecting a fractionation zone bottoms portion comprising at least ninety-nine mole percent of the hydrocarbons heavier than methane entering the fractionation zone and no more than one percent of the methane entering the fractionation zone; collecting a fractionation zone overheads portion comprising mostly methane; and separating a hydrogen stream from at least one of the plurality of chilling stages operated at a temperature lower than -140° C.

Claim 3

A process as recited in claim 1 wherein the fractionation zone overheads portion contains less than one mole percent of the hydrocarbons heavier than methane contained in the gas mixture.

Claim 4

A process as recited in claim 1 wherein the fractionation zone bottoms portion contains less than 1000 ppm wt. methane, less than 100 ppm wt. hydrogen and less than 100 ppm wt. carbon monoxide.

Claim 5

A process as recited in claim 1 wherein the hydrogen stripper overheads portion contains at least ninety mole percent of the hydrogen passed to the hydrogen stripper and less than thirty percent of the methane passed to the hydrogen stripper.

Claim 6

A process as recited in claim 1 wherein the fractionation zone overheads portion contains less than three mole percent hydrogen.

Claim 7

A process as recited in claim 1 wherein the hydrogen stream is comprised of more than ninety mole percent hydrogen and contains at least ninety mole percent of the hydrogen contained in the gas mixture passed through the plurality of chilling stages.

Claim 8

A process as recited in claim 1 wherein the hydrogen stripper overheads portion is passed to at least one of the plurality of chilling stages.

Claim 9

A process as recited in claim 1 wherein the hydrogen stripper overheads portion is passed to a point upstream of the plurality of chilling stages.

Claim 10

A process for separating hydrogen and methane from a gas mixture containing hydrocarbons heavier than methane, said process comprising the steps of: providing the option of precluding the need to utilize an external methane refrigeration circuit by, passing the mixture through a plurality of chilling stages; collecting at least one chilling stage bottoms portion from at least one of the plurality of chilling stages; passing at least one chilling stage bottoms portion to a hydrogen stripper; collecting a hydrogen stripper overheads portion containing at least ninety percent of the hydrogen entering the hydrogen stripper; collecting a hydrogen stripper bottoms portion containing at least seventy percent of the methane passed to the hydrogen stripper and at least ninety-nine mole percent of the hydrocarbons heavier than methane passed to the hydrogen stripper; passing the hydrogen stripper overheads portion to at least one of the plurality of chilling stages; passing the hydrogen stripper bottoms portion to a fractionation zone; collecting a fractionation zone bottoms portion containing at least ninety-nine mole percent of the hydrocarbons heavier than methane, said fractionation zone bottoms portion containing less than 1000 ppm wt. methane, less than 100 ppm wt. hydrogen and less than 100 ppm wt. carbon monoxide; collecting a fractionation zone overheads portion comprising at least ninety five mole percent methane; and collecting a hydrogen overheads portion from at least one of the plurality of chilling stages operated at a temperature lower than -140° C.

Claim 11

A process for separating hydrogen and methane from a gas mixture containing hydrocarbons heavier than methane, said process comprising the steps of: providing the option of precluding the need to utilize an external methane refrigeration circuit by, passing the mixture through a plurality of chilling stages; collecting at least one chilling stage bottoms portion from at least one of the plurality of chilling stages; passing at least one chilling stage bottoms portion to a hydrogen stripper; collecting a hydrogen stripper overheads portion containing at least ninety percent of the hydrogen entering the hydrogen stripper; collecting a hydrogen stripper bottoms portion containing at least seventy percent of the methane passed to the hydrogen stripper and at least ninety-nine mole percent of the hydrocarbons heavier than methane passed to the hydrogen stripper; passing the hydrogen stripper overheads portion to at least one of the plurality of chilling stages; passing the hydrogen stripper bottoms portion to a fractionation zone; collecting a fractionation zone bottoms portion containing at least ninety-nine mole percent of the hydrocarbons heavier than methane, said fractionation zone bottoms portion containing less than 1000 ppm wt. methane, less than 100 ppm wt. hydrogen and less than 100 ppm wt. carbon monoxide; collecting a fractionation zone overheads portion comprising at least ninety five mole percent methane; and collecting a hydrogen overheads portion from at least one of the plurality of chilling stages operated at a temperature lower than -140° C.

Claim 12

A process as recited in claim 9 wherein the hydrogen overheads portion is comprised of more than 90 mole percent hydrogen.

Claim 13

A process as recited in claim 9 wherein the hydrogen overheads portion contains at least 90% of the hydrogen contained in the gas mixture passed through the plurality of chilling stages.

Claim 14

A process as recited in claim 9 wherein the fractionation zone overheads portion contains less than three percent hydrogen.

Claim 15

A process for separating hydrogen and methane from a gas mixture containing hydrocarbons heavier than methane, said process comprising the steps of: providing the option of precluding the need to utilize an external methane refrigeration circuit by, passing the mixture through a plurality of chilling stages; collecting at least one chilling stage bottoms portion from at least one of the plurality of chilling stages; passing at least one chilling stage bottoms portion to a hydrogen stripper; collecting a hydrogen stripper overheads portion containing at least ninety percent of the hydrogen entering the hydrogen stripper; collecting a hydrogen stripper bottoms portion containing at least seventy percent of the methane passed to the hydrogen stripper; passing the hydrogen stripper bottoms portion to a fractionation zone; collecting a fractionation zone bottoms portion containing at least ninety-nine mole percent of the hydrocarbons heavier than methane entering the fractionation zone; collecting a fractionation zone overheads portion comprising mostly methane; separating a hydrogen stream containing more than ninety mole percent hydrogen from at least one of the plurality of chilling stages operated at a temperature lower than -140° C.; separating a hydrogen bleed stream from the hydrogen stream; combining the hydrogen bleed stream with the fractionation zone overheads portion to form a chilled fractionation zone overheads portion; and collecting a methane stream from the chilled fractionation zone overheads portion.

Claim 16

A process for separating hydrogen and methane from a gas mixture containing hydrocarbons heavier than methane, said process comprising the steps of: providing the option of precluding the need to utilize an external methane refrigeration circuit by, passing the mixture through a plurality of chilling stages; collecting at least one chilling stage bottoms portion from at least one of the plurality of chilling stages; passing at least one chilling stage bottoms portion to a hydrogen stripper; collecting a hydrogen stripper overheads portion containing at least ninety percent of the hydrogen entering the hydrogen stripper; collecting a hydrogen stripper bottoms portion containing at least seventy percent of the methane passed to the hydrogen stripper; passing the hydrogen stripper bottoms portion to a fractionation zone; collecting a fractionation zone bottoms portion containing at least ninety-nine mole percent of the hydrocarbons heavier than methane entering the fractionation zone; collecting a fractionation zone overheads portion comprising mostly methane; separating a hydrogen stream containing more than ninety mole percent hydrogen from at least one of the plurality of chilling stages operated at a temperature lower than -140° C.; separating a hydrogen bleed stream from the hydrogen stream; combining the hydrogen bleed stream with the fractionation zone overheads portion to form a chilled fractionation zone overheads portion; and collecting a methane stream from the chilled fractionation zone overheads portion.

Claim 17

A process as recited in claim 13 wherein the fractionation zone overheads portion contains less than one mole percent of the hydrocarbons heavier than methane contained in the gas mixture and less than three percent hydrogen; the fractionation zone bottoms portion contains less than 1000 ppm wt. methane, less than 100 ppm wt. hydrogen and less than 100 ppm wt. carbon monoxide; and the hydrogen stream contains at least ninety percent of the hydrogen contained in the gas mixture passed through the plurality of chilling stages.

Claim 18

A process for separating hydrogen and methane from a gas mixture containing heavier hydrocarbons, said process comprising the steps of: providing the option of precluding the need to utilize an external methane refrigeration circuit by, passing the mixture through a plurality of chilling stages; collecting a first bottoms portion from at least one chilling stage; passing the first bottoms portion to a hydrogen stripper; collecting a hydrogen stripper overheads portion containing at least ninety percent of the hydrogen entering the hydrogen stripper; collecting a hyrogen stripper bottoms portion which comprises at least seventy percent of the methane entering the hydrogen stripper; passing the hydrogen stripper bottoms portion to a fractionation zone; collecting a second bottoms portion from at least one of the plurality of chilling stages; passing the second bottoms portion to the fractionation zone; collecting a fractionation zone bottoms portion comprising at least ninety-nine mole percent of the hydrocarbons heavier than methane entering the fractionation zone; collecting a fractionation zone overheads portion comprising mostly methane and; collecting a hydrogen stream at least one chilling stage operated at a temperature lower than -140° C.

Claim 19

A process for separating hydrogen and methane from a gas mixture containing heavier hydrocarbons, said process comprising the steps of: providing the option of precluding the need to utilize an external methane refrigeration circuit by, passing the mixture through a plurality of chilling stages; collecting a first bottoms portion from at least one chilling stage; passing the first bottoms portion to a hydrogen stripper; collecting a hydrogen stripper overheads portion containing at least ninety percent of the hydrogen entering the hydrogen stripper; collecting a hyrogen stripper bottoms portion which comprises at least seventy percent of the methane entering the hydrogen stripper; passing the hydrogen stripper bottoms portion to a fractionation zone; collecting a second bottoms portion from at least one of the plurality of chilling stages; passing the second bottoms portion to the fractionation zone; collecting a fractionation zone bottoms portion comprising at least ninety-nine mole percent of the hydrocarbons heavier than methane entering the fractionation zone; collecting a fractionation zone overheads portion comprising mostly methane and; collecting a hydrogen stream at least one chilling stage operated at a temperature lower than -140° C.

Claim 20

A process as recited in claim 15 wherein the fractionation zone overheads portion is passed through a heat exchange zone in which the methane stream is collected.

Claim 21

A process as recited in claim 15 wherein each successive stage of the plurality of chilling stages is operated at a temperature which is lower than the temperature of the chilling stage which preceded it.

Claim 22

A process as recited in claim 15 wherein the first bottoms portion is collected from at least the first chilling stage of the plurality of chilling stages.

Claim 23

A process as recited in claim 15 wherein the hydrogen stripper overheads portion is passed to a chilling stage at a colder temperature than the coldest chilling stage from which the first bottoms portion was taken.

Claim 24

A process as recited in claim 15 wherein the hydrogen stream is collected from the chilling stage of lowest temperature.

Claim 25

In a process for separating hydrogen and methane from a gas mixture having hydrocarbons heavier than methane in which the mixture is passed through a plurality of chilling stages, each successive chilling stage being colder than the one preceding it, a bottoms portion and overheads portion being collected from at least one of the chilling stages, the bottoms portion being passed to a fractionation zone, the overheads portion being passed to a hydrogen separator, collecting a fractionation zone bottoms portion comprising substantially all of the hydrocarbons heavier than methane entering the fractionation zone, and collecting a methane rich stream from the fractionation zone, the improvement comprising the steps of: providing the option of precluding the need to utilize an external methane refrigeration circuit by, collecting a bottoms portion from at least one chilling stage; passing the bottoms portion from at least one chilling stage to a hydrogen stripper; collecting a hydrogen stripper bottoms portion comprising at least seventy percent of the methane entering the hydrogen stripper; passing the hydrogen stripper bottoms portion to the fractionation zone; collecting a hydrogen stripper overheads portion containing most of the hydrogen entering the stripper; passing the hydrogen stripper overheads portion to a chilling stage at a lower temperature than the coldest chilling stage from which the bottoms portion passed to the hydrogen stripper was taken; collecting a methane stream from the fractionation zone overheads portion; and collecting a hydrogen stream from a chilling stage of a temperature lower than -140° C.

Claim 26

In a process for separating hydrogen and methane from a gas mixture having hydrocarbons heavier than methane in which the mixture is passed through a plurality of chilling stages, each successive chilling stage being colder than the one preceding it, a bottoms portion and overheads portion being collected from at least one of the chilling stages, the bottoms portion being passed to a fractionation zone, the overheads portion being passed to a hydrogen separator, collecting a fractionation zone bottoms portion comprising substantially all of the hydrocarbons heavier than methane entering the fractionation zone, and collecting a methane rich stream from the fractionation zone, the improvement comprising the steps of: providing the option of precluding the need to utilize an external methane refrigeration circuit by, collecting a bottoms portion from at least one chilling stage; passing the bottoms portion from at least one chilling stage to a hydrogen stripper; collecting a hydrogen stripper bottoms portion comprising at least seventy percent of the methane entering the hydrogen stripper; passing the hydrogen stripper bottoms portion to the fractionation zone; collecting a hydrogen stripper overheads portion containing most of the hydrogen entering the stripper; passing the hydrogen stripper overheads portion to a chilling stage at a lower temperature than the coldest chilling stage from which the bottoms portion passed to the hydrogen stripper was taken; collecting a methane stream from the fractionation zone overheads portion; and collecting a hydrogen stream from a chilling stage of a temperature lower than -140° C.