Modularization Of A Hydrocarbon Processing Plant

Abstract

A hydrocarbon processing plant, such an LNG plant, is disclosed. A piperack structure has a major axis parallel to the major axis of the train with which it is associated. A first multipurpose module, substantially pre-assembled prior to being transported to an operating location, has a major axis that is either parallel or perpendicular to the major axis of the piperack. The first multipurpose module contains: process components that perform a function related to hydrocarbon processing or handling; piping systems that connect the process components directly to a second module that is adjacent the first multipurpose module, and wherein at least part of the piping systems are aligned with the major axis of the piperack structure; and at least one heat exchanger located in the first multipurpose module and operationally connected to process components in the hydrocarbon processing plant.

What is claimed is: 
     
         1 . A hydrocarbon processing plant, comprising:
 a train having a major axis;   a piperack structure having a major axis that is parallel to the major axis of the train;   a first multipurpose module, configured to be substantially pre-assembled prior to being transported to an operating location, the first multipurpose module having a major axis that is parallel to the major axis of the piperack, the first multipurpose module containing
 process components that perform a function related to hydrocarbon processing or handling, 
 piping systems that connect the process components directly to a second module, where the second module is adjacent the first multipurpose module, and wherein at least part of the piping systems are aligned with the major axis of the piperack structure, and 
 at least one heat exchanger located in the first multipurpose module and operationally connected to process components in the hydrocarbon processing plant. 
   
     
     
         2 . The hydrocarbon processing plant of  claim 1 , wherein the first multipurpose module is part of a liquefied natural gas facility. 
     
     
         3 . The hydrocarbon processing plant of  claim 1 , wherein the function performed by the process components contained in the first multipurpose module is removal of acid gas from a natural gas stream. 
     
     
         4 . The hydrocarbon processing plant of  claim 3 , further comprising an amine solvent unit used for the removal of acid gas. 
     
     
         5 . The hydrocarbon processing plant of  claim 3 , further comprising an amine absorber and at least one amine regenerator column, wherein the amine absorber and the at least one amine regenerator column are configured to be erected and connected to the process components at an installation site of the hydrocarbon processing plant. 
     
     
         6 . The hydrocarbon processing plant of  claim 1 , wherein the function performed by the process components contained in the first multipurpose module is removal of water from a natural gas stream. 
     
     
         7 . The hydrocarbon processing plant of  claim 6 , wherein the process components contained in the first multipurpose module comprise molecular sieve adsorption beds arranged in a sequence that is parallel to the major axis of the piperack structure. 
     
     
         8 . The hydrocarbon processing plant of  claim 7 , wherein the molecular sieve adsorption beds are first molecular sieve adsorption beds, and further comprising second molecular sieve adsorption beds located in the first multipurpose module and associated with extraction of C 6   30   components from a natural gas stream, wherein the first and second molecular sieve adsorption beds are arranged in a sequence that is parallel to the major axis of the piperack structure. 
     
     
         9 . The hydrocarbon processing plant of  claim 1 , wherein the function performed by the process components contained in the first multipurpose module is extraction of C 6   +  components from a natural gas stream. 
     
     
         10 . The hydrocarbon processing plant of  claim 9 , wherein the process components contained in the first multipurpose module comprise one or more of a scrub column and a Joule-Thompson assembly. 
     
     
         11 . The hydrocarbon processing plant of  claim 1 , wherein the function performed by the process components contained in the first multipurpose module is mechanical refrigeration of a natural gas stream accomplished in part by rejecting heat to an ambient using one or more air and/or water-cooled heat exchangers. 
     
     
         12 . The hydrocarbon processing plant of  claim 11 , wherein the mechanical refrigeration is accomplished in part by
 a refrigerant comprising propane and/or propylene, or   a mixed refrigerant comprising methane, ethane and/or ethylene, and propane and/or propylene.   
     
     
         13 . The hydrocarbon processing plant of  claim 12 , wherein the mixed refrigerant further comprises butane. 
     
     
         14 . The hydrocarbon processing plant of  claim 1 , further comprising operating site-built or operating site-assembled components connected to the first multipurpose module, the operating site-built or operating site-assembled components performing part of the function associated with the process components contained in the first multipurpose module. 
     
     
         15 . The hydrocarbon processing plant of  claim 1 , wherein the second module is a second multipurpose module configured to be substantially pre-assembled prior to being transported to the operating location, the second multipurpose module containing process components that perform a function related to hydrocarbon processing or handling different from the function performed by the process components of the first multipurpose module. 
     
     
         16 . The hydrocarbon processing plant of  claim 1 , wherein the second module is a piperack module configured to be substantially pre-assembled prior to being transported to the operating location. 
     
     
         17 . The hydrocarbon processing plant of  claim 1 , wherein the second module has a major axis that is one of parallel to and perpendicular to the major axis of the piperack structure. 
     
     
         18 . The hydrocarbon processing plant of  claim 1 , further comprising a heat exchanger bank running along the major axis of the train. 
     
     
         19 . The hydrocarbon processing plant of  claim 1 , wherein the at least one heat exchanger is aligned with the major axis of the first multipurpose module. 
     
     
         20 . A method of constructing a hydrocarbon processing plant, comprising:
 providing a train at an operating site, the train having a major axis;   providing a piperack structure at the operating site, the piperack structure having a major axis that is parallel to the major axis of the train;   providing a heat exchanger bank running along the major axis of the train;   substantially pre-assembling a first multipurpose module at a manufacturing site that is separate from the operating site, the first multipurpose module including   process components that perform a function related to hydrocarbon processing or handling,   piping systems, and   a plurality of heat exchangers operationally connected to process components in the train, wherein the plurality of heat exchangers are aligned with a major axis of the first multipurpose module;   transporting the first multipurpose module to the operating site; and   operationally connecting, at the operating site, the first multipurpose module to the train such that (a) a major axis of the first multipurpose module is either parallel or substantially perpendicular to the major axis of the piperack, (b) the piping systems connect the process components directly to a second module that is adjacent the first multipurpose module, and (c) at least part of the piping systems are aligned with the major axis of the piperack structure.   
     
     
         21 . The method of  claim 20 , wherein the function performed by the process components contained in the first multipurpose module is removing acid gas from a natural gas stream, and further comprising: erecting and connecting an amine absorber and at least one amine regenerator column to the process components at the operating site. 
     
     
         22 . The method of  claim 20 , further comprising erecting and connecting, at the operating site, one or more components to the first multipurpose module, the one or more components performing part of the function associated with the process components contained in the first multi-purpose module. 
     
     
         23 . The method of  claim 20 , wherein the function performed by the process components contained in the first multipurpose module is removing water from a natural gas stream. 
     
     
         24 . The method of  claim 23 , wherein the process components contained in the first multipurpose module comprise molecular sieve adsorption beds, and further comprising arranging the molecular sieve adsorption beds in a sequence that is parallel to the major axis of the piperack structure. 
     
     
         25 . The method of  claim 24 , wherein the molecular sieve adsorption beds are first molecular sieve adsorption beds, and further comprising:
 locating second molecular sieve adsorption beds in the first multipurpose module, the second molecular sieve adsorption beds being associated with extraction of C 6   +  components from a natural gas stream; and   arranging the first and second molecular sieve adsorption beds in a sequence that is parallel to the major axis of the piperack structure.   
     
     
         26 . The method of  claim 20 , wherein the function performed by the process components contained in the first multipurpose module is mechanical refrigeration of a natural gas stream that is accomplished in part by rejecting heat to an ambient using one or more air and/or water-cooled heat exchangers. 
     
     
         27 . The method of  claim 26 , wherein the mechanical refrigeration is accomplished in part by
 a refrigerant comprising propane and/or propylene, or   a mixed refrigerant comprising methane, ethane and/or ethylene, and propane and/or propylene.   
     
     
         28 . The method of  claim 20 , wherein the second module is a second multipurpose module containing process components that perform a function related to hydrocarbon processing or handling different from the function performed by the process components of the first multipurpose module, and further comprising:
 substantially pre-assembling the second multipurpose module prior to being transported to the operating location; and   connecting the second multipurpose module to the first multipurpose module at the operating location.   
     
     
         29 . The method of  claim 20 , wherein the second module is a piperack module that forms part of the piperack structure, the method further comprising:
 pre-assembling the piperack module prior to being transported to the operating location; and   connecting the piperack module to other portions of the piperack structure and to the first multipurpose module at the operating location.