Process and apparatus for separating mixtures of hydrogen and carbon monoxide

A process for separating hydrogen and carbon monoxide from a condensate-containing synthesis gas produced by catalytic conversion or partial oxidation of natural gas, oils or other hydrocarbon feedstock thereof, said process comprising:

• scrubbing the gaseous mixture with a liquid methane wash stream in a methane wash column to provide a gaseous hydrogen product stream, a “first” liquid CO-loaded methane stream and a feed gas condensate removed from a location vertically spaced from removal of said CO-loaded methane;
• separating said first liquid CO-loaded methane stream into a gaseous hydrogen-rich stream and a liquid CO/methane stream in a “first” stripping column;
• separating said CO/methane stream into a gaseous carbon monoxide stream and a liquid methane stream in a separation column;
• separating said feed gas condensate into a “second” gaseous hydrogen-enriched stream and a “second” liquid CO/methane stream in a “second” stripping column or a flash separator;
• feeding the second gaseous hydrogen-enriched stream to the first stripping column;
• and
• feeding the second liquid CO/methane stream to the separation column.

A process for separating hydrogen and carbon monoxide from a condensate-containing synthesis gas produced by catalytic conversion or partial oxidation of natural gas, oils or other hydrocarbon feedstock thereof, said process comprising:

• scrubbing the gaseous mixture with a liquid methane wash stream in a methane wash column to provide a gaseous hydrogen product stream, a liquid CO-loaded methane stream and a feed gas condensate removed from a location vertically spaced from removal of said CO-loaded methane;
• separating said CO-loaded methane stream into a gaseous hydrogen-rich stream and a “first” liquid CO/methane stream in a “first” stripping column;
• splitting said first liquid CO/methane stream into at least “first” and “second” substreams;
• subcooling said first substream and introducing the subcooled liquid into a separation column for separating the CO/methane stream into a gaseous carbon monoxide stream and a liquid methane stream;
• at least partially vaporizing said second substream and introducing it into the separation column at a location below that of said subcooled first substream;
• separating said feed gas condensate into a “second” gaseous hydrogen-enriched stream and a “second” liquid CO/methane stream in a “second” stripping column or a flash separator;
• feeding the second gaseous hydrogen-enriched stream to the first stripping column;
• splitting said second liquid CO/methane stream into at least “third” and “fourth” substreams;
• subcooling said third substream and introducing the subcooled liquid into the separation column;
• and
• at least partially vaporizing said fourth substream and introducing it into the separation column at a location below that of the said subcooled third substream.

A process for separating hydrogen and carbon monoxide from a condensate-containing synthesis gas produced by catalytic conversion or partial oxidation of natural gas, oils or other hydrocarbon feedstock thereof, said process comprising:

• phase separating said condensate-containing gas mixture to provide a feed gas condensate and feed vapor;
• scrubbing said feed vapor with a liquid methane wash stream in a methane wash column to provide a gaseous hydrogen product stream and a liquid CO-loaded methane stream;
• separating said CO-loaded methane stream into a gaseous hydrogen-rich stream and a “first” liquid CO/methane stream in a “first” stripping column;
• separating said first liquid CO/methane stream into a gaseous carbon monoxide stream and a liquid methane stream in a separation column;
• separating said feed gas condensate into a “second” gaseous hydrogen-enriched stream and a “second” liquid CO/methane stream in a “second” stripping column or a flash separator;
• feeding the second gaseous hydrogen-enriched stream to the first stripping column;
• and
• feeding the second liquid CO/methane stream to the separation column.

A process for separating hydrogen and carbon monoxide from a condensate-containing synthesis gas produced by catalytic conversion or partial oxidation of natural gas, oils or other hydrocarbon feedstock thereof, said process comprising:

• phase separating said condensate-containing gas mixture to provide a feed gas condensate and feed vapor;
• scrubbing said feed vapor with a liquid methane wash stream in a methane wash column to provide a gaseous hydrogen product stream and a liquid CO-loaded methane stream;
• separating said CO-loaded methane stream into a gaseous hydrogen-rich stream and a “first” liquid CO/methane stream in a “first” stripping column;
• splitting said first liquid CO/methane stream into at least “first” and “second” substreams;
• subcooling said first substream and introducing the subcooled liquid into a separation column for separating the CO/methane stream into a gaseous carbon monoxide stream and a liquid methane stream;
• at least partially vaporizing said second substream and introducing it into the separation column at a location below that of said subcooled first substream;
• wherein
• separating said feed gas condensate into a “second” gaseous hydrogen-enriched stream and a “second” liquid CO/methane stream in a “second” stripping column or a flash separator;
• feeding the second gaseous hydrogen-enriched stream to the first stripping column;
• splitting said second liquid CO/methane stream into at least “third” and “fourth” substreams;
• subcooling said third substream and introducing the subcooled liquid into the separation column;
• and
• at least partially vaporizing said fourth substream and introducing it into the separation column at a location below that of the said subcooled third substream.

An apparatus for separating hydrogen and carbon monoxide from a condensate-containing gaseous mixture thereof, said apparatus comprising:

• a methane wash column;
• phase separation means for removing feed gas condensate from the gaseous mixture to provide a feed vapor,
• means for feeding the feed vapor to the methane wash column;
• a “first” stripping column;
• a carbon monoxide/methane separation column;
• means for feeding CO-loaded methane from the methane wash column to the first stripping column;
• means for feeding liquid CO/methane from the first stripping column to the separation column;
• and
• means for recycling liquid methane from the separation column to the methane wash column,
• wherein the apparatus further comprises
• a second stripping column or a flash separator;
• means for feeding feed gas condensate from the phase separation means to the second stripping column or flash separator;
• means for feeding a “second” second gaseous hydrogen-enriched stream from the second stripping column or flash separator to the first stripping column;
• and
• means for feeding a “second” liquid CO/methane stream to the separation column.

An apparatus for separating hydrogen and carbon monoxide from a condensate-containing gaseous mixture thereof, said apparatus comprising:

• a methane wash column having a sump;
• means for feeding the gas mixture to the methane wash column;
• a “first” stripping column;
• a carbon monoxide/methane separation column;
• means for feeding CO-loaded methane from a location of the methane wash column above the feed thereto to the first stripping column;
• means for feeding liquid CO/methane from the first stripping column to the separation column;
• and
• means for recycling liquid methane from the separation column to the methane wash column,
• wherein the apparatus further comprises
• a second stripping column or a flash separator;
• means for feeding feed gas condensate from the sump of the methane wash column to the second stripping column or flash separator;
• means for feeding a “second” second gaseous hydrogen-enriched stream from the second stripping column or flash separator to the first stripping column;
• and
• means for feeding a “second” liquid CO/methane stream to the separation column.