CN1135350C - 制取液化天然气的气态富甲烷给料的液化方法 - Google Patents
制取液化天然气的气态富甲烷给料的液化方法 Download PDFInfo
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Abstract
与制冷剂蒸发逆向地在主热交换器(1)中冷却、液化和次级冷却富甲烷给料,得到一种液化流,并将液化流作为液化产品通入(80)储存器。该液化方法是通过使用以预控制模式为基础的先进过程控制器来控制的,该控制模式同步地确定一组操作变量的控制动作,以便在控制一组控制变量中的至少一个变量时使一组参数中至少一个参数被最优化,其中一组操作变量包括重制冷剂部分(52)的质量流率,轻制冷剂部分(59)的质量流率和富甲烷给料(20)的质量流率,其中控制变量包括主热交换器(1)热端(3)的温度差和主热交换器(1)中间点(7)处的温度差,其中一组需要最优化的参数包括液化产品(80)的产量。
Description
本发明涉及制取液化产品的气态富甲烷给料的液化方法。该液化产品通常称作液化天然气。
澳大利亚专利第AU-B-75223/87号公开了这样一种方法。已知的控制方法对三种情况有不同的步骤,(1)在液化产品的生产低于所需速度的地方,考虑到主热交换器冷端的温度差,应该通过调整制冷剂的组分来增加速度;(2)在生产大于所需速度的地方,应该通过减小制冷剂压缩机的吸入压力来降低速度;以及(3)在生产处于理想速度的地方,应该将制冷剂总量维持在预定的范围内来使总设备的效率最佳化。在(1)和(2)的情况下,相对于总效率,制冷剂总量、组分以及制冷剂的压缩率应该是最佳的。
当生产处于理想速度时,最好首先要检验制冷剂总量。接着连续调整与制冷剂有关的变量:重制冷剂部分与轻制冷剂部分制冷剂的质量流率、制冷剂中氮含量以及C3∶C2的比率,以便达到最高效率。然后调整制冷剂压缩机的压缩比来达到最高效率。最佳化的最后步骤是调整制冷剂压缩机的速度。
当其它临界参数,例如主热交换器冷端和热端的温度差低于或高于预定的值或范围时,设置报警,此时,自动控制过程停止。
已知控制方法的缺点在于它需要连续调整制冷剂组分,以便使生产最佳化。另一个缺点是连续地进行最佳化,且自动过程控制不能处理例如主热交换器热端的温度差超过预定范围的情况。
为了克服这些缺点,液化产品方法包括以下步骤:
(a)以升高的压力在主热交换器的热端向主热交换器第一管提供气态富甲烷给料,与制冷剂的蒸发逆向冷却、液化和过冷气态富甲烷给料以便得到一种液化流,在主热交换器的冷端从主热交换器中排出液化流,并作为一种液化产物使该液化流通入储存器;
(b)在主热交换器的热端从主热交换器的壳体中排出蒸发的制冷剂;
(c)在至少一个制冷剂压缩机中压缩蒸发的制冷剂以便得到高压制冷剂;
(d)部分冷凝高压制冷剂,并将该部分冷凝的制冷剂分成液态的重制冷剂部分和气态的轻制冷剂部分;
(e)在主热交换器的第二管过冷重制冷剂部分以得到一种过冷的重制冷剂流,在主热交换器的中间点处以降低的压力将重制冷剂流引入主热交换器的壳体内,并使重制冷剂流在壳体内蒸发,
(f)在主热交换器的第三管冷却、液化和过冷至少部分轻制冷剂以得到一种过冷轻制冷剂流,以降低的压力在主热交换器的冷端将轻制冷剂流引入主热交换器的壳体内,并使轻制冷剂流在壳体内蒸发;以及
(g)使用一个过程控制器控制液化方法以同时确定用于一组操作变量的控制作用,以便优化一个参数,同时控制一组控制变量中的至少一个。
本发明制取液化天然气的气态富甲烷给料的液化方法的特征在于过程控制器基于模型预测控制,其中一组操作变量包括重制冷剂部分的质量流率、轻制冷剂部分的质量流率和富甲烷给料的质量流率,其中一组控制变量包括在主热交换器热端的温度差,此差值是在第一管中的流体和在主热交换器热端壳体中的流体之间的温度差,以及在主热交换器中间处的温度差,此差值是在第一管中的流体和在主热交换器中间点处的温度差,并且其中一组需要最佳化的参数包括液化产品的产量。
在说明书和权利要求中所述的“最佳变量”通常指的是将变量最大化或最小化,以及将变量保持在预定值上。
预控制模式或以预控制为基础的模式是已知技术,例如Perry’sChemical Engineers’Handbook,第7版第8-25至8-27页。该预控制模式的关键技术在于应用一种模式和可得到的控制变量的测量来判断未来的过程行为。计算控制器的输出来使性能指标最佳化,该性能指标是预测误差和计算出的未来控制动作的一次或二次函数。在每个采样瞬间,控制计算被重复进行,并且根据当前的测量修正前置量。一个适当的模式是一种包括表示控制变量基础上的操作变量阶跃响应作用的一组经验阶跃响应模型。
需要最佳化的参数的最佳值能够从单独的最佳化步骤中得到,或者需要最佳化的变量能够包含在特性函数中。
在能够应用预控制模式之前,人们首先确定需要最佳化的变量和控制变量基础上操作变量阶跃变化的作用。这导致了一组阶跃响应系数。这一组阶跃响应系数形成液化方法预控制模式的基础。
在正常操作期间,为了许多未来的控制动作,有规律地计算控制变量的预测值。为了这些未来的控制动作而计算性能指标。该性能指标包括两项,第一项表示对于每个控制动作的预测误差的未来控制动作的总和,第二项表示对于每个控制动作操作变量中的变化的未来控制动作的总和。对每个控制变量来说,预测误差不同于控制变量的预测值,也不同于控制变量的参考值。预测误差与一个加权因数一起增加,并且与每个控制动作相应的操作变量中的变化与一个抑制因数一起增加。这里讨论的性能指标是线性的。
或者,在性能指标是二次方程的情况下,这些项可以是平方项的和。
此外,限制因素能够确定操作变量、操作变量中的变化和控制变量。这导致单独一套与性能指标最小化同时解决的方程式。
可以用两种方法进行最佳化,一个方法是分别进行最佳化,超出性能指标的最小限度,第二种方法是在性能指标内进行最佳化。
当分别进行最佳化时,需要最佳化的参数作为控制动作预测误差中的控制变量存在,并且最佳化为控制变量提供一个参考值。
或者,最佳化在性能指标的计算中进行,并且与适当的加权因数一起给出性能指标中的第三项。在这种情况下,控制变量的参考值是保持恒定的预先确定的稳定状态值。
在考虑限制条件的情况下,性能指标被最小化来给出未来控制动作的操作值。然而,只执行下一个控制动作。接着再计算未来控制动作启动的性能指标。
具有阶跃响应系数的模式和预控制模式中所需的方程式是计算机所执行的控制液化过程的程序的一部分。装载这种能够处理预控制模式的程序的计算机被称作先进的过程控制器。由于计算机程序在商业上是很有用的,我们将不详细讨论这种程序。本发明更着重于选择各种变量。
现在将参照附图详细描述本发明的实施例,其中
图1示意性地表示了液化天然气厂的流程图;以及
图2示意性地表示了丙烷的冷却循环。
现在参照图1,液化天然气厂包括一个具有热端3、冷端5和中间点7的主热交换器1。主热交换器1的壁限定了一壳体10。在壳体10中设置一个从热端3延伸至冷端5的第一管13,一个从热端3延伸至中间点7的第二管15,以及一个从热端3延伸至冷端5的第三管16。
在正常操作期间,使气态富甲烷给料以升高的压力通过供给管20在主热交换器的热端3进入主热交换器1的第一管13。该给料通过第一管13时与在壳体10中蒸发的制冷剂逆向被冷却、液化和过冷。结果从主热交换器1的冷端5通过管路23排出液化流体。然后将该液化流通入储存器,在储存器中该液化流被作为一种液化产品来储存。
从主热交换器的热端3通过管路25将蒸发的制冷剂排出主热交换器1的壳体10。在制冷剂压缩机30和31中将蒸发的制冷剂压缩成高压制冷剂,该制冷剂通过管路32排出。
第一制冷剂压缩机30由适当的电机驱动,例如气体透平机35,该透平机具有一个启动辅助电机36,第二制冷压缩机31由适当的电机驱动,例如具有辅助电机(未示出)的气体透平机37。在两个压缩机30和31之间,压缩热被通过空气冷却器40和热交换器41中的管路38中的流体带走。
管路32中的高压制冷剂在空气冷却器42中冷却,并在热交换器43中部分冷凝得到部分冷凝的制冷剂。
该高压制冷剂通过入口装置46被送入一个独立的容器45中。在该独立容器45中,部分冷凝的制冷剂被分成液态的重制冷剂部分和气态的轻制冷剂部分。液态的重制冷剂部分通过管路47从独立容器45中排出,而气态的轻制冷剂部分通过管路48从独立容器45中排出。
重制冷剂部分在主热交换器1的第二管15中进行过冷,得到一种过冷重制冷剂流。该过冷重制冷剂流通过管路50从主热交换器1中排出,并在膨胀阀51这种形式的膨胀装置上进行膨胀。在减小压力的情况下,该流体通过管路52和喷嘴53在主热交换器的中间点7处进入主热交换器1的壳体10。使该重制冷剂流以减低的压力在壳体10中蒸发,由此冷却管13、15和16中的流体。
由管路48排出的气态轻制冷剂部分中的一部分通过管路55进入主热交换器1的第三管16,并在其中被冷却、液化和过冷,得到一种过冷轻制冷剂流。该过冷轻制冷剂流通过管路57从主热交换器1中排出,并在膨胀阀58这种形式的膨胀装置上膨胀。在压力减小的情况下,该制冷剂流通过管路59和喷嘴60在主热交换器的冷端5进入主热交换器1的壳体10。使该轻制冷剂流以减低的压力在壳体10中膨胀,由此冷却管13、15和16中的流体。
由管路48排出的剩下的轻制冷剂部分通过管路61进入热交换器63,并在该热交换器中被冷却、液化和过冷。在管路64上从热交换器63到管路59之间设置一个膨胀阀65。
所得到的液化流通过管路23排出主热交换器1并通入闪蒸容器70。该管路23上设置一个膨胀阀71这种形式的膨胀装置,以便减小压力,这样得到的液化流以减低的压力经入口装置72引入闪蒸容器70。降低的压力一般等于大气压。膨胀阀也可调整总流量。
从闪蒸容器70的顶部经过管路75排出产出气体。该产出气体在一个由电机78驱动的尾部闪蒸压缩机(end-flash compressor)77中被压缩,得到高压燃料气体,此燃料气体通过管路79排出。所述的产出气体对热交换器63中的轻制冷剂部分进行冷却、液化和过冷。
液化的产品通过管路80从闪蒸容器70的底部排出并通入储存器(未示出)中。
第一个目的是要将通过由阀81操作的管线80的液化产品的产量最大化。
上述预控制模式被用来达到这个目的。这组操作变量包括通过管路52(膨胀阀51)的重制冷剂部分的质量流率,通过管路59(膨胀阀58和62)的轻制冷剂部分的质量流率,以及通过管路20(该管路由阀71操作)的富甲烷给料的质量流率。而这组控制变量包括主热交换器1的热端3的温度差(该温度差是管路47中流体温度与管路25中流体温度的差),以及主热交换器1的中间点7处的温度差(该温度差是管路50中流体温度与主热交换器中间点处壳体10内的流体温度的差)。通过选择这些变量,可实现对具有以预控制模式为基础的先进控制过程的主热交换器1的控制。
申请人已发现当使用预控制模式以及使用重制冷剂部分质量流率、轻制冷剂质量流率和富甲烷给料质量流率作操作变量时,能够得到有效、迅速的控制,这样使液化产品的产量最佳化并控制主热交换器中的温度分布。
本发明的这种先进方法在于不是通过操作混合制冷剂中主要组分来使液化产品的产量达到最佳化。
为了整套设备的完整,显然管路80上装有一个流量控制阀81,该阀由液面控制器82操作来确保正常操作期间闪蒸容器70中保持足够的液面高度。然而,根据本发明,由于在进入闪蒸容器70的流入物与流出闪蒸容器70的流出物相匹配时阀81不动作,因此流量控制阀81的存在与最佳化无关。
在液化产物的产量已经被维持在一个预定的水平上时,预控制模式控制主热交换器1中的温度分布。为了这个目标,一组控制变量还包括通过管路23排出主热交换器1的液化流的温度。
本发明的另一个目的是使压缩机的利用率达到最大限度。为了要达到这个目的,一组操作变量还包括制冷剂压缩机30和31的压缩速率。
通过管路20供给主热交换器1的气态富甲烷给料是从天然气给料中得到的,通过部分冷凝天然气给料得到供给主热交换器1的气相部分冷凝给料。该天然气给料通过供给管90。至少在热交换器93中进行部分冷凝。
部分冷凝给料经过入口装置94进入净化塔95。在该净化塔中,部分冷凝给料被分馏形成气态的塔顶馏出的气流以及一种液态的废甲烷(methane-depleted)的底部流。该气态塔顶馏出流经过管路97通入热交换器100,在热交换器100中,该气态塔顶馏出流被部分冷凝,并且该部分冷凝的塔顶馏出流经入口装置103进入上部分离器102。在该上部分离器102中,部分冷凝馏出流被分成气态富甲烷流和一种液态底部流。
通过管路104排出的气态富甲烷流在管路20中形成气态富甲烷给料。至少部分底部液体流通过管路105和喷嘴106作为逆向流引入净化塔95。管路105上设有一个流量控制阀108,该阀是由一个液面控制器109操作来保持上部分离器102中的一个固定液面的。
如果所需逆向流比部分冷凝液态塔顶馏出流中的液体少的话,剩余的逆向流可经过具有流量控制阀112的管路111通到主热交换器1中。这样,一组操作变量包括流过管路111的过量底部流的质量流率。
在只需要很少逆向流的情况下,可以经过带有流量控制阀114的管路113从原料处(未示出)加入丁烷。在这种情况下,操作变量还包括流过管路113的含丁烷流的质量流率。
液态的废甲烷的底部流经管路115从净化塔95中排出。为了提供洗涤用的蒸汽,液态废甲烷的底部流通过与如管路119提供的热水或蒸汽这样适当的热介质进行间接热交换的方式在热交换器118中蒸发。该蒸汽通过管路120被引入净化塔95的下部,并且液体经管路122从热交换器118中排出,该管路122具有一个由液面控制器124操作的流量控制阀123,以此在热交换器118的壳体内维持一个固定的液面高度。
为了将净化塔95的控制与主热交换器1的控制结合起来,一组操作变量还包括管路122中液态废甲烷底部流的温度。因而,一组控制变量还包括气态富甲烷流(管路104中)中较重碳氢化合物的浓度、管路122中液态废甲烷底部流中甲烷的浓度和逆向流质量流率,即流过管路105的逆向流质量流率。需要最佳化的参数还包括液化产品的发热值。该发热值是根据流过管路80中液化产品的组分分析来计算的。这种分析可借助于色谱法进行。
管路122中液态废甲烷底部流的温度通过调节热交换器118的热输入来调节。
在几个实例中,热交换器用于从液体,例如部分冷凝的液体中去除热量。在热交换器41中从压缩的制冷剂中去除热量,在热交换器43中,高压制冷剂被部分冷凝,在热交换器93中天然气供给料被部分冷凝,并且在热交换器100中气态的塔顶馏出流被部分冷凝。在这些热交换器中,借助于与适当压力下丙烷蒸发进行间接热交换可去除热量。
图2简要示出了丙烷循环。蒸发的丙烷在由一个合适的电机,如气体透平机128驱动的丙烷压缩机127中被压缩。丙烷在空气冷却器130中被冷凝,并且在升高的压力下冷凝的丙烷经过管路135和136进入热交换器93和43,此两个热交换器被布置为相互并行的。该冷凝的丙烷在进入热交换器93和43之前在膨胀阀137和138中膨胀达到一个较高的中间压力。气态的部分经过管路140和141到达丙烷压缩机127的一个入口。液态部分经过管路145和146到达热交换器41。在进入热交换器41之前,丙烷在膨胀阀148上膨胀达到一个较低的中间压力。气态部分经过管路150到达丙烷压缩机127的一个入口。液态部分经过管路151到达热交换器100。在进入热交换器41之前,丙烷在膨胀阀152中膨胀到一个较低的压力。该较低压力下的丙烷经过管路153通到丙烷压缩机127的一个入口。
为了将丙烷循环的控制与主热交换器1的控制结合起来,一组操作变量还包括丙烷压缩机127的压缩速率,进而一组控制变量还包括第一丙烷压缩机127的吸入压力,即管路153中丙烷的压力。这种方法可使丙烷压缩机的利用率最高。
在丙烷压缩机包括两个串联的压缩机时,一组操作变量还包括两个丙烷压缩机的压缩速率,进而一组控制变量还包括第一丙烷压缩机的吸入压力。
为了进一步优化该方法,一组控制变量还可包括尾部闪蒸压缩机77的负荷。
分别控制制冷剂的主要组分和制冷剂总量(未示出)以便补偿由于泄露而产生的损失。这种控制是属于先进的控制主热交换器方法之外的。
下面的表1和2是权利要求书所给出的主要操作和控制变量。
表1
权利要求书中的主要操作变量
| 权利要求 | 变量 | 参考标号 |
| 1 | 重制冷剂部分的质量流率 | 51 |
| 1 | 轻制冷剂部分的质量流率 | 58、62 |
| 1 | 富甲烷给料的质量流率 | 71 |
| 3 | 制冷剂压缩机压缩速率 | 30、31 |
| 7 | 液态废甲烷底部流的温度 | 122 |
| 8 | 含丁烷流的质量流率 | 113 |
| 8 | 过量液态底部流的质量流率 | 111 |
| 10 | 丙烷压缩机压缩速率 | 127 |
表2
权利要求书中的主要控制变量
| 权利要求 | 变量 | 参考标号 |
| 1 | 主热交换器热端的温度差 | 3 |
| 1 | 主热交换器中间点处的温度差 | 7 |
| 2 | 从主热交换器排出的液化流的温度 | 23 |
| 7 | 气态富甲烷流中较重碳氢化合物的浓度 | 104 |
| 7 | 液态废甲烷底部流中甲烷的浓度 | 122 |
| 7 | 液态废甲烷底部流的质量流率 | 122 |
| 7 | 逆向流质量流率 | 105 |
| 10 | 第一丙烷压缩机的吸入压力 | 153 |
| 11 | 尾部闪蒸压缩机的负荷 | 77 |
Claims (12)
1.液化气态富甲烷给料产生液化产品的方法,该液化方法包括以下步骤:
(a)在主热交换器的热端以升高的压力将气态富甲烷给料供给主热交换器的第一管,与制冷剂的蒸发逆向地冷却、液化和过冷该气态富甲烷给料,以便得到一种液化流,在主热交换器的冷端将该液化流排出主热交换器,并将该液化流作为一种液化产品通入储存器;
(b)在主热交换器的热端将蒸发的制冷剂从主热交换器的壳体中排出;
(c)在至少一个制冷剂压缩机中压缩该蒸发的制冷剂得到高压制冷剂;
(d)部分冷凝该高压制冷剂,并将该部分冷凝的高压制冷剂分成液态的重制冷剂部分和气态的轻制冷剂部分;
(e)在主热交换器的第二管中对重制冷剂进行过冷得到过冷重制冷剂流,在主热交换器的中间点处以降低的压力将重制冷剂流引入主热交换器的壳体中,并使该重制冷剂流在壳体中蒸发;
(f)在主热交换器的第三管中冷却、液化和过冷至少部分轻制冷剂部分,以便得到过冷轻制冷剂流,在主热交换器的冷端以降低的压力将轻制冷剂流引入主热交换器的壳体中,并使该轻制冷剂流在壳体内蒸发,以及
(g)使用一个过程控制器控制液化方法以同时确定用于一组操作变量的控制作用,以便最优化一个参数,同时控制一组控制变量中的至少一个;
其特征在于过程控制器基于模型预测控制,其中所述一组操作变量包括重制冷剂部分的质量流率、轻制冷剂部分的质量流率和富甲烷给料的质量流率,其中所述一组控制变量包括在主热交换器热端的温度差,此差值是在第一管中的流体和在主热交换器热端壳体中的流体之间的温度差,以及在主热交换器中间处的温度差,此差值是在第一管中的流体和在主热交换器中间点处的温度差,并且其中需要最优化的所述参数是液化产品的产量。
2.如权利要求1所述的方法,其特征在于所述一组控制变量还包括从主热交换器排出的液化流的温度。
3.如权利要求1或2所述的方法,其特征在于所述一组操作变量还包括制冷剂压缩机的压缩速率,以最大地利用压缩机。
4.如权利要求1或2所述的方法,其特征在于步骤(d)中高压制冷剂的部分冷凝是借助于与适当压力下丙烷蒸发进行间接热交换的方式在至少一个热交换器中进行的。
5.如权利要求1或2所述的方法,其特征在于气态富甲烷给料是通过部分冷凝天然气给料而从天然气给料中得到的,进而获得部分冷凝给料。
6.如权利要求5所述的方法,其特征在于对天然气的部分冷凝是通过与适当压力下丙烷蒸发进行间接热交换的方式在至少一个热交换器中进行的。
7.如权利要求5所述的方法,其特征在于,还包括在净化塔中分馏部分冷凝的给料以得到气态塔顶馏出流和液态废甲烷底部流;部分冷凝气态塔顶馏出流;以及将气态馏出流分成形成气态富甲烷给料的气态富甲烷流和至少部分作为逆向流通过净化塔的液态底部流,其特征在于所述一组操作变量还包括液态废甲烷底部流的温度,所述一组控制变量还包括气态富甲烷流中较重碳氢化合物的浓度,液态废甲烷底部流中甲烷的浓度,液态富甲烷底部流的质量流率和逆向流质量流率,以及需要最优化的另一个参数是液化产品的发热值。
8.如权利要求7所述的方法,还包括向逆向流中加入含丁烷流,其特征在于所述一组操作变量还包括过量底部流的质量流率和/或含丁烷流的质量流率。
9.如权利要求7或8所述的方法,其特征在于借助与适当压力下丙烷蒸发进行间接热交换的方式在至少一个热交换器中对气态塔顶馏出流进行部分冷凝。
10.如权利要求4所述的方法,其中在至少一个丙烷压缩机中压缩蒸发的丙烷并通过与外部的冷却液进行热交换来冷凝,其特征在于所述一组操作变量还包括丙烷压缩机的压缩速率,所述一组控制变量还包括第一丙烷压缩机的吸入压力。
11.如权利要求1或2所述的方法,其特征在于还包括降低液化流的压力得到通入储存器的液化产品和排出气体;还包括在尾部闪蒸压缩机中排出气体成为高压燃料气,其特征在于所述一组控制变量还包括尾部闪蒸压缩机的负荷。
12.如权利要求1或2所述的方法,其特征在于还包括分别控制制冷剂的主要组分和制冷剂总量。
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| EP97203915 | 1997-12-12 | ||
| EP97203915.0 | 1997-12-12 |
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| EP1036293B1 (en) | 2002-04-10 |
| EA002008B1 (ru) | 2001-10-22 |
| NO20002956L (no) | 2000-08-04 |
| JP2002508499A (ja) | 2002-03-19 |
| KR100521705B1 (ko) | 2005-10-14 |
| US6272882B1 (en) | 2001-08-14 |
| DZ2671A1 (fr) | 2003-03-22 |
| AU732548B2 (en) | 2001-04-26 |
| PT1036293E (pt) | 2002-09-30 |
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