Apparatus and process for the refrigeration, liquefaction and separation of gases with varying levels of purity

A process for separating and cooling one or more components of a pressurized mixed gas stream, the process comprising the steps of:

• a. cooling the pressurized mixed gas stream in a first heat exchanger to condense a first component thereof;
• b. separating the condensed first component from the mixed gas stream, thereby creating a first component stream in a liquid state;
• c. passing the first component stream through a first expander so as to cool the first component stream;
• and
• d. using the expanded first component stream to cool the mixed gas stream.

A process for separating one or more components from natural gas comprising:

• a. feeding a natural gas stream from a gas well to a heat exchanger solely under the natural gas pressure produced by the gas well, the heat exchanger cooling the natural gas so as to condense a first component thereof;
• b. separating the condensed first component from the natural gas stream, thereby creating a first component stream in a liquid state;
• c. passing the first component stream through an expander so as to cool the first component stream;
• and
• d. using the expanded first component stream to cool the natural gas stream.

A process for liquefying gas comprising:

• a. feeding a gas stream through a heat exchanger so as to cool the gas stream;
• b. passing the cooled gas stream through a turbo expander so as to produce energy and to convert the gas stream into a liquid phase and a vapor phase;
• and
• c. operating a compressor from the energy produced at least in part by the turbo expander, the compressor compressing the gas stream prior to feeding into the heat exchanger.

A process for liquefying gas comprising:

• a. feeding a gas stream through a heat exchanger so as to cool the gas stream;
• b. passing the cooled gas stream through a turbo expander so as to produce energy and to convert the gas stream into a liquid phase and a vapor phase;
• c. compressing the vapor phase produced by the turbo expander in a compressor, the compressor being at least partially operated from the energy produced by the turbo expander;
• d. cooling the compressed vapor phase;
• and
• e. passing the cooled vapor phase through heat exchanger so as to cool the gas stream passing therethrough.

A process for separating and cooling components of a pressurized mixed gas stream comprising the steps of:

• a. cooling a pressurized mixed gas stream comprising a first component, a second component, and a third component, the mixed gas stream being sufficiently cooled to condense the first component;
• b. separating the condensed first component from the mixed gas stream, thereby creating a first component stream in a liquid state;
• c. cooling the first component stream by way of expansion;
• d. using the expanded first component stream to cool the mixed gas stream;
• e. further cooling the mixed gas stream after the first component is separated therefrom so as to condense the second component;
• f. separating the condensed second component from the mixed gas stream, thereby creating a second component stream in a liquid state;
• g. cooling the second component stream by way of expansion;
• and
• h. using the expanded second component stream to cool the mixed gas stream.

A gas processing system, comprising:

• a. a first heat exchanger configured to receive a mixed gas stream having a plurality of components;
• b. a first gas-liquid separator fluid coupled with the first heat exchanger, the first gas-liquid separator having a liquid stream outlet;
• c. a first expander fluid coupled with the liquid stream outlet of the first gas-liquid separator, the first expander also being fluid coupled with the first heat exchanger so as to facilitate cooling of the mixed gas stream when the mixed gas stream flows through the first heat exchanger;
• d. a final heat exchanger fluid coupled to the gas stream outlet of the first gas-liquid separator;
• e. a final expander fluid coupled with the second heat exchanger down stream thereof;
• and
• f. a final gas-liquid separator fluid coupled with the second expander down stream thereof.

A mobile gas processing system, comprising:

• a. a trailer having a frame with wheels mounted thereon;
• b. a mixed gas processing system mounted on the trailer, the processing system comprising:
• (i) a first heat exchanger configured to receive the mixed gas stream;
• (ii) a first gas-liquid separator fluid coupled with the first heat exchanger, the first gas-liquid separator having a liquid stream outlet and a gas stream outlet;
• and
• (iii) a first expander fluid coupled with the liquid stream outlet of the first gas-liquid separator, the first expander also being fluid coupled with the first heat exchanger so as to facilitate cooling of the mixed gas stream when the mixed gas stream flows through the first heat exchanger;
• c. a second heat exchanger fluid coupled with the gas stream outlet of the first gas-liquid separator;
• d. a second gas-liquid separator fluid coupled with the second heat exchanger, the first gas-liquid separator having a liquid stream outlet and a gas stream outlet;
• and
• e. a second expander fluid coupled with the liquid stream outlet of the second gas-liquid separator, the second expander also being fluid coupled with the second heat exchanger so as to facilitate cooling of the mixed gas stream when the mixed gas stream flows through the second heat exchanger.